Indexing apparatus and method of indexing

ABSTRACT

An indexing apparatus includes a fixture tool, movable relative to an operation cell, and an indexing feature, fixed relative to the fixture tool. The indexing apparatus also includes a plurality of probes, configured to engage the indexing feature. The indexing apparatus further includes a controller, in communication with the plurality of probes, wherein the controller is configured to locate the fixture tool relative to the operation cell from a plurality of probe locations of the plurality of probes, engaged with the indexing feature.

PRIORITY

This application claims priority from U.S. Ser. No. 63/115,103 filed onNov. 18, 2020.

FIELD

The present disclosure generally relates to manufacturing and, moreparticularly, to an indexing apparatus and method of indexing during amanufacturing operation.

BACKGROUND

Many structures, parts, and components are manufactured using largeautomated machines that have a fixed base and that operate along apredetermined toolpath under computer control. Such manufacturingtechniques require accurate indexing of a workpiece relative to themachine. One method of indexing the workpiece is to probe the workpieceat different locations to align, or “zero”, a work tool of the machinewith the immediate location of the workpiece based on the probedlocations. Another method of indexing the workpiece is to secure theworkpiece at a specific, repeatable location using a fixture. However,both methods can be time consuming and expensive processes, whichrequire extensive set-up each time the workpiece is moved to a new worklocation or a new workpiece is moved to the work location. This problemis exacerbated for large structures, such as aircraft spars, wingsections, fuselage sections, and the like, which may require anextremely large number of probe locations or extremely large fixtures.Furthermore, neither of these methods are conducive for continuousmanufacturing in which there is a need to quickly and accurately movethe workpiece from one work location to another work location.Accordingly, those skilled in the art continue with research anddevelopment efforts in the field of indexing during manufacturing and,as such, apparatuses and methods intended to address theabove-identified concerns would find utility.

SUMMARY

The following is a non-exhaustive list of examples, which may or may notbe claimed, of the subject matter according to the present disclosure.

In an example, a disclosed indexing apparatus includes a fixture tool,movable relative to an operation cell, and an indexing feature, fixedrelative to the fixture tool. The indexing apparatus also includes aplurality of probes, configured to engage the indexing feature. Theindexing apparatus further includes a controller, in communication withthe plurality of probes, wherein the controller is configured to locatethe fixture tool relative to the operation cell from a plurality ofprobe locations of the plurality of probes, engaged with the indexingfeature.

In an example, a disclosed manufacturing system includes an automatedmachine, located in an operation cell and configured to perform at leastone manufacturing operation. The manufacturing system also includes afixture tool, configured to support a workpiece and movable relative tothe operation cell, and an indexing feature, fixed relative to thefixture tool. The manufacturing system further includes a plurality ofprobes, configured to engage the indexing feature. The manufacturingsystem also includes a controller, in communication with the pluralityof probes and the automated machine. The controller is configured tolocate the fixture tool relative to the operation cell from a pluralityof probe locations of the plurality of probes, engaged with the indexingfeature. The controller is further configured to index the automatedmachine relative to a fixture-tool location of the fixture tool.

In an example, a disclosed method of manufacturing includes steps of:(1) moving a fixture tool relative to an operation cell; (2) engaging anindexing feature with a plurality of probes; (3) locating the fixturetool relative to the operation cell from a plurality of probe locationsof the plurality of probes, engaged with the indexing feature; and (4)indexing an automated machine relative to a fixture-tool location of thefixture tool.

Other examples of the disclosed apparatus, system, and method willbecome apparent from the following detailed description, theaccompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic block diagram of an example of an indexingapparatus;

FIG. 2 is a schematic, perspective view of an example of a manufacturingsystem using the indexing apparatus;

FIG. 3 is a schematic, perspective view of an example of an interfacingdevice, an indexing feature, and a fixture tool of the indexingapparatus;

FIG. 4 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 5 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 6 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 7 is a schematic block diagram of an example of a processingoperation used to determine a location of a fixture tool of the indexingapparatus;

FIG. 8A is a schematic, perspective view of an example of a gripper ofthe interfacing device of the indexing apparatus;

FIG. 8B is a schematic, perspective view of an example of the indexingfeature of the indexing apparatus;

FIG. 9A is a schematic, perspective view of an example of the gripper ofthe interfacing device of the indexing apparatus;

FIG. 9B is a schematic, perspective view of an example of the indexingfeature of the indexing apparatus;

FIG. 10 is a schematic, perspective plan view of an example of themanufacturing system;

FIG. 11 is a schematic, perspective view of an example of themanufacturing system using the indexing apparatus;

FIG. 12 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 13 is a schematic, perspective view of an example of theinterfacing device, the indexing feature, and the fixture tool of theindexing apparatus;

FIG. 14 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 15 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 16 is a schematic block diagram of an example of the processingoperation used to determine the location of the fixture tool of theindexing apparatus;

FIG. 17 is a schematic, perspective view of an example of the indexingfeature and the fixture tool of the indexing apparatus;

FIG. 18 is a schematic, perspective view of an example of the indexingfeature and the fixture tool of the indexing apparatus;

FIG. 19 is a schematic, perspective view of an example of the indexingfeature and the fixture tool of the indexing apparatus;

FIG. 20 is a schematic, perspective plan view of an example of themanufacturing system;

FIG. 21 is a schematic, perspective view of an example of themanufacturing system using the indexing apparatus;

FIG. 22 is a schematic, top plan view of an example of the indexingapparatus;

FIG. 23 is a schematic, perspective view of an example of theinterfacing device, the indexing feature, and the fixture tool of theindexing apparatus;

FIG. 24 is a schematic block diagram of an example of the processingoperation used to determine the location of the fixture tool of theindexing apparatus;

FIG. 25 is a schematic, elevational view of an example of the indexingfeature and the fixture tool of the indexing apparatus;

FIG. 26 is a schematic, elevational view of an example of the indexingfeature and the fixture tool of the indexing apparatus;

FIG. 27 is a schematic, elevational view, in partial section, of anexample of a probe of the interfacing device, the indexing feature, andthe fixture tool of the indexing apparatus;

FIG. 28 is a schematic, perspective plan view of an example of themanufacturing system;

FIG. 29 is a flow diagram of an example of a method of manufacturing;

FIG. 30 is a flow diagram of an example of a method of manufacturing;

FIG. 31 is a flow diagram of an example of a method of manufacturing;

FIG. 32 is a schematic block diagram of an example of a controller ofthe indexing apparatus;

FIG. 33 is a flow diagram of an aircraft manufacturing and servicemethodology; and

FIG. 34 is a block diagram of an aircraft.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings,which illustrate specific examples described by the present disclosure.Other examples having different structures and operations do not departfrom the scope of the present disclosure. Like reference numerals mayrefer to the same feature, element, or component in the differentdrawings.

Illustrative, non-exhaustive examples, which may be, but are notnecessarily, claimed, of the subject matter according the presentdisclosure are provided below. Reference herein to “example” means thatone or more feature, structure, element, component, characteristic,and/or operational step described in connection with the example isincluded in at least one embodiment and/or implementation of the subjectmatter according to the present disclosure. Thus, the phrases “anexample,” “another example,” “an example,” and similar languagethroughout the present disclosure may, but do not necessarily, refer tothe same example. Further, the subject matter characterizing any oneexample may, but does not necessarily, include the subject mattercharacterizing any other example. Moreover, the subject mattercharacterizing any one example may be, but is not necessarily, combinedwith the subject matter characterizing any other example.

Referring generally to FIGS. 1-33 , by way of examples, the presentdisclosure describes an indexing apparatus 100 used to locate and indexa workpiece 170 during a manufacturing operation, a manufacturing system168 that utilizes the indexing apparatus 100, and methods 1000, 2000,3000 of manufacturing that utilize the indexing apparatus 100 to locateand index the workpiece 170.

FIG. 1 schematically illustrates an example of the indexing apparatus100. Generally, the indexing apparatus 100 provides a means foraccurately and repeatably determining a location of the workpiece 170relative to a reference frame 216 defined by a fixed coordinate system112. FIG. 1 also schematically illustrates an example of themanufacturing system 168 that includes the indexing apparatus 100. Themanufacturing system 168 includes, or forms at least a portion of, anoperation cell 106. An automated machine 128 is located within theoperation cell 106 and is configured to perform at least onemanufacturing operation on the workpiece 170. The operation cell 106 isdefined, or is described, by the fixed coordinate system 112 andincludes a work envelope 140. The work envelope 140 forms athree-dimensional volume within the operation cell 106, described by thefixed coordinate system 112, in which the automated machine 128operates.

Referring to FIG. 1 , the indexing apparatus 100 includes a fixture tool102. The fixture tool 102 is configured to securely hold the workpiece170. The fixture tool 102 includes various suitable holding-features 260that enable the workpiece 170 to be secured on or to otherwise be heldto the fixture tool 102. The fixture tool 102 is movable relative to theoperation cell 106, for example, relative to the automated machine 128located within the operation cell 106. For example, the fixture tool102, along with the workpiece 170 that is secured to the fixture tool102, is moved to a work location 258 within the work envelope 140 of theoperation cell 106.

As used herein, the term “work location 258” generally refers to aspatial situation of the fixture tool 102 and, thus, the workpiece 170,when the fixture tool 102 is moved within the operation cell 106 forperformance of at least one manufacturing operation on the workpiece 170by the automated machine 128. The present disclosure recognizes andtakes into account that when the fixture tool 102 is moved within theoperation cell 106, the work location 258 may not be precisely known.Accordingly, the indexing apparatus 100 is configured to determine alocation of the fixture tool 102 (also referred to herein as afixture-tool location 118) and, thus, a location of the workpiece 170(also referred to herein as a workpiece location 262) relative to thereference frame 216, when the fixture tool 102 is at the work location258.

The indexing apparatus 100 includes an indexing feature 104. Theindexing feature 104 is fixed relative to the fixture tool 102. In otherwords, a location of the indexing feature 104 relative to the fixturetool 102 is constant regardless of the location (or change in location)of the fixture tool 102 relative to the reference frame 216. In anexample, the indexing feature 104 is coupled to the fixture tool 102. Inanother example, the indexing feature 104 is located on the fixture tool102. In yet another example, the indexing feature 104 forms a part of(e.g., is integral to) the fixture tool 102.

Throughout the present disclosure, the term “location” refers to thelinear situation of an object along one or more orthogonal axes inthree-dimensional space, such as along the fixed coordinate system 112.Additionally, in some instances, the term “location” also refers to theangular situation (e.g., orientation) of the object about one or moreorthogonal axes in three-dimensional space, such as about the fixedcoordinate system 112. Generally, the “location” of an object refers toan X-location of at least a portion of one or more external surfaces ofthe object (e.g., the X-coordinates of a plurality of pointsrepresenting at least a portion of the external surface), a Y-locationof at least a portion of one or more external surfaces of the object(e.g., the Y-coordinates of the plurality of points representing atleast a portion of the external surface), and a Z-location of at least aportion of one or more external surfaces of the object (e.g., theZ-coordinates of the plurality of points representing at least a portionof the external surface).

Referring still to FIG. 1 , the indexing apparatus 100 includes aninterfacing device 220. The interfacing device 220 is configured tointerface with the indexing feature 104 and to locate the indexingfeature 104 relative to the reference frame 216, such as within theoperation cell 106. The interfacing device 220 is configured to generateinterface data 222 that is representative of a location of the indexingfeature 104 (also referred to herein as an indexing-feature location116) relative to the reference frame 216. As will be described ingreater detail herein, the interfacing device 220 may interface with andlocate the indexing feature 104 using at least one of a gripper 108, asensor 184, and a plurality of probes 202.

The indexing apparatus 100 also includes a controller 110. Thecontroller 110 is in communication (e.g., electrical and/or datacommunication) with the interfacing device 220. The controller 110 isconfigured to process the interface data 222, generated by theinterfacing device 220, and to determine the indexing-feature location116, based on the interface data 222. The controller 110 is alsoconfigured to determine an immediate (e.g., a real-time, actual)location of the fixture tool 102 and, thus, the workpiece 170 relativeto the reference frame 216, based on the indexing-feature location 116.The automated machine 128 is indexed relative to the fixture tool 102,based on the determined location of the fixture tool 102 (thefixture-tool location 118).

In the disclosed examples, a geometry of the workpiece 170, a geometryof the fixture tool 102, and a geometry of the indexing feature 104 areknown. As used herein, the “geometry” of an object refers to the size,shape, and form of the object as well as any surface contours of theobject. The geometry of the object may include an interior geometry ofthe object and/or an exterior geometry of the object. For example, thegeometry of the workpiece 170 describes the size, shape, and form of theworkpiece 170 as well as any surface contours of the workpiece 170.

Additionally, the workpiece 170 is fixed to or is otherwise secured tothe fixture tool 102 at a known location relative to the fixture tool102. In other words, a location of the workpiece 170 (the workpiecelocation 262) relative to the fixture tool 102 is known and remainsconstant regardless of the location (or change in location) of thefixture tool 102 relative to the reference frame 216, such as when thefixture tool 102 moves into or out of the operation cell 106. Similarly,the location of the workpiece 170 is also fixed and remains constantrelative to the indexing feature 104.

Therefore, the indexing-feature location 116 can be used to determinethe fixture-tool location 118. In turn, the fixture-tool location 118can be used to assume the workpiece location 262 within tolerance. Inother words, the fixture-tool location 118 represents the immediatelocation of the fixture tool 102 and the workpiece 170 relative to thereference frame 216. As such, throughout the present disclosure, unlessotherwise specified, the term “fixture-tool location 118” isrepresentative of and incorporates the location of the workpiece 170(the workpiece location 262).

In an example, prior to initiation of a locating and indexing operation,the controller 110 is configured to identify the fixture tool 102, theindexing feature 104, and the workpiece 170 upon which the manufacturingoperation is to be performed. In an example, a type of fixture tool, atype of indexing feature, and/or a type of workpiece may be loaded intothe program before execution of locating and indexing instructions. Inanother example, the program may actively identify and select the typeof fixture tool, the type of indexing feature, and/or the type ofworkpiece from a database of options based on one or more predeterminedselection criteria.

The geometry of the fixture tool 102, the geometry of the indexingfeature 104, and the geometry of the workpiece 170 are therefore knownbased on the type of fixture tool 102, the type of indexing feature 104,and/or the type of workpiece 170 identified by the controller 110. Forexample, the program loads a digital model 120 representing the fixturetool 102, the indexing feature 104, and the workpiece 170. The geometryof the fixture tool 102 (also referred to herein as fixture-toolgeometry 264), the geometry of the indexing feature 104 (also referredto herein as indexing-feature geometry 266), and the geometry of theworkpiece 170 (also referred to herein as workpiece geometry 268) arerepresented by or are extracted from the digital model 120 (FIG. 1 ).

In an example, the digital model 120 includes digital representations ofthe fixture tool 102, the indexing feature 104, and the workpiece 170.In another example, the digital model 120 includes a digitalrepresentation of a combination of the fixture tool 102 with theindexing feature 104 and the workpiece 170 secured to the fixture tool102. Thus, the digital model 120 represents the location of the indexingfeature 104 and/or the workpiece 170 relative to the fixture tool 102.

Referring still to FIG. 1 , during the locating and indexing operation,the controller 110 is configured to match the indexing-feature geometry266 to the indexing-feature location 116 represented by the interfacedata 222. For example, the controller 110 registers the geometricrepresentation of the indexing feature 104 of the digital model 120 tothe indexing-feature location 116. The controller 110 then determines alocation of the digital model 120 relative to the reference frame 216(referred to herein as a model location 126), thereby locating thedigital model 120 in the reference frame 216. Registration of thedigital model 120 with the indexing-feature location 116 may beperformed using any one of a variety of data computing techniques thatbest aligns a set of data points (e.g., representing the digital model120) with a set of reference data points (e.g., representing theindexing-feature location 116), such as point cloud transformation. Thecontroller 110 then determines the location of the fixture tool 102 andthe location of the workpiece 170 (the fixture-tool location 118)relative to the reference frame 216 based on the model location 126. Forexample, the fixture-tool location 118 is assumed to be the modellocation 126 within tolerance.

The automated machine 128 is then indexed relative to the fixture tool102, based on the fixture-tool location 118 relative to the referenceframe 216. The automated machine 128 operates along a well-defined,programmed (e.g., numerically controlled) cycle of motions, or toolpath, relative to the reference frame 216 in at least one dimension ofthe fixed coordinate system 112.

In an example, the automated machine 128 includes a robotic arm 226,having multiple degrees of freedom, and an end effector 228 that iscoupled to a working end of the robotic arm 226. The end effector 228includes, or takes the form of, at least one work tool that isconfigured to perform at least one manufacturing operation on theworkpiece 170. The robotic arm 226 is configured to move the endeffector 228 along a predetermined toolpath under computer controlrelative to the fixture tool 102 and the workpiece 170, based on thefixture-tool location 118.

Generally, the locating and indexing operations described herein can beperformed in conjunction with, or as an initial step in association withany, one of various types of additive or subtractive manufacturingoperations. As such, the automated machine 128 may perform any one ofvarious types of manufacturing operations on the workpiece 170,including, but not limited to, a drilling operation, a millingoperation, a fastening operation, pre-cure and/or post-cure compositeassembly operations (e.g., a material layup operation, a laminatingoperation, etc.) and the like. Generally, the end effector 228 includesa suitable tool that is configured to perform the associatedmanufacturing operation.

Because the geometry of the workpiece 170 is known and because thelocation of the workpiece 170 is known, or is assumed within tolerance,relative to the fixture tool 102, indexing the automated machine 128relative to the fixture tool 102, based on the fixture-tool location118, consequently indexes the automated machine 128 relative to theworkpiece 170. Once the automated machine 128 is indexed relative to thefixture-tool location 118, the automated machine 128 operates along theprogrammed tool path to perform at least one manufacturing operation onthe workpiece 170 in a known manner. The geometry of the workpiece 170and the known location of the workpiece 170 relative to the fixture tool102 are incorporated in and are accounted for by the programmed toolpath of the automated machine 128.

The present disclosure recognizes and takes into account that thegeometry of the workpiece 170 may change as a result of themanufacturing (e.g., assembly or machining) operation performed on theworkpiece 170. However, the location of the workpiece 170 relative tothe fixture tool 102 and the indexing feature 104 does not change due toactions outside of the manufacturing operations. Therefore, any flexing,shifting, or the like of the workpiece 170 are within tolerance duringthe manufacturing operation and do not have an out of tolerance effecton the location of the workpiece 170. In other words, at each stop alonga complete manufacturing process, the only change to the workpiece 170is in geometry due to the various manufacturing operations.

Changes in the geometry of the workpiece 170 resulting from any of themanufacturing operations are also known, or are assumed withintolerance, based on theoretical addition or subtraction from a previousmanufacturing operation. For example, the workpiece geometry 268 (e.g.,represented by the digital model 120) is updated based on the additiveor subtractive manufacturing operation performed on the workpiece 170.

When the fixture tool 102 and the workpiece 170 are moved to asubsequent work location 258, such as to a second operation cell 172 forperformance of a subsequent manufacturing operation on the workpiece 170by a second automated machine 174 (FIGS. 10, 20, and 28 ), the indexingfeature 104 is located, the fixture-tool location 118 is determined, andthe second automated machine 174 is indexed relative to the fixture-toollocation 118 as described herein. The known (e.g., changed) geometry ofthe workpiece 170 and the known location of the workpiece 170 relativeto the fixture tool 102 are incorporated in and are accounted for by theprogrammed tool path of the second automated machine 174. Therefore,such changes to the workpiece geometry 268 are taken into account insubsequent locating and indexing operations, which in turn, enablesrepeatable indexing based on the location of the fixture tool 102.

Accordingly, the examples of the indexing apparatus 100, themanufacturing system 168, and the methods 1000, 2000, 3000 disclosedherein enable the workpiece 170 to be quickly and accurately located,without the need for an expensive and time-consuming set up operation orlocating operation. The automated machine 128 can, in turn, be quicklyand precisely indexed relative to the fixture tool 102 and, thus, theworkpiece 170, based on the determined location of the fixture tool 102.

FIGS. 1-29 , schematically illustrate various example implementations ofthe interfacing device 220 and the indexing feature 104 of the disclosedindexing apparatus 100. As illustrated in FIGS. 1-10 , in an example,the interfacing device 220 includes at least one gripper 108 thatprovides a contact interface with the indexing feature 104. Asillustrated in FIGS. 11-21 , in an example, the interfacing device 220includes at least one sensor 184 that provides a noncontact interfacewith the indexing feature 104. As illustrated in FIGS. 22-29 , in anexample, the interfacing device 220 includes a plurality of probes 202that provides a contact interface with the indexing feature 104.

Referring generally to FIG. 1 and particularly to FIGS. 2-4 , in anexample, the indexing apparatus 100 includes the fixture tool 102. Thefixture tool 102 is movable relative to the operation cell 106. Theindexing apparatus 100 also includes the indexing feature 104. Theindexing feature 104 is fixed relative to the fixture tool 102. Forexample, the indexing feature 104 is coupled to the fixture tool 102. Inan example, the indexing feature 104 extends from the fixture tool 102.

In the examples illustrated in FIGS. 2-5 , the indexing feature 104 iscoupled to and extends from a front end of the fixture tool 102. Inother examples, the indexing feature 104 is coupled to, or is locatedon, another portion (e.g., a side, a rear, a bottom, etc.) of thefixture tool 102.

In an example, the indexing apparatus 100 includes the gripper 108. Thegripper 108 is movable relative to the operation cell 106 and thefixture tool 102. The gripper 108 is configured to engage (e.g., to makephysical contact with) the indexing feature 104. The indexing feature104 is appropriately located relative to the fixture tool 102 so that atleast a portion of the indexing feature 104 is physically accessible bythe gripper 108. Conversely, the gripper 108 is appropriately locatedrelative to the fixture tool 102 so that at least a portion of thegripper 108 is physically accessible by the indexing feature 104. Withthe gripper 108 engaged to the indexing feature 104, a location of thegripper 108 (also referred to herein as a gripper location 114) (FIG. 1) is representative of, or corresponds to, the indexing-feature location116 (FIG. 1 ). In other words, the gripper 108 locates the indexingfeature 104 in the reference frame 216.

Referring to FIGS. 2-6 , in an example, the gripper 108 includes anarticulation mechanism 230 and a grip head 232 that is coupled to aworking end of the articulation mechanism 230. The articulationmechanism 230 has multiple degrees of freedom and is configured to movethe grip head 232 in three-dimensional space, such as linearly along atleast one axis of the fixed coordinate system 112 and/or rotationallyabout at least one axis of the fixed coordinate system 112.

The grip head 232 is configured to engage the indexing feature 104. Forexample, the grip head 232 is configured to grasp or otherwise firmlyhold at least a portion of the indexing feature 104. With the grip head232 engaged to the indexing feature 104, the gripper location 114 is alocation of the grip head 232 and is representative of, or correspondsto, the indexing-feature location 116.

The articulation mechanism 230 includes at least one suitable drivemotor (not shown) to drive motion of the articulation mechanism 230,such as an electromechanical motor, a pneumatic motor, a hydraulicmotor, and the like. The articulation mechanism 230 is also configuredto provide location data (e.g., the interface data 222) that representsthe gripper location 114, for example, relative to the reference frame216 in at least one dimension of the fixed coordinate system 112. Forexample, the articulation mechanism 230 also includes at least oneencoder (not shown) and/or at least one sensor (not shown) that convertsmotion of the articulation mechanism 230 into an electrical signal thatrepresents the gripper location 114. The articulation mechanism 230 alsoincludes other suitable electronic, mechanical, pneumatic, and hydrauliccomponents (not shown). The articulation mechanism 230 operates undercomputer control, such as by the controller 110.

Referring to FIGS. 2 and 4 , in an example, the articulation mechanism230 is coupled to, or forms a portion of, the automated machine 128. InFIG. 4 , the robotic arm 226 and the end effector 228 (FIG. 2 ) of theautomated machine 128 (e.g., for performing the at least onemanufacturing operation) are removed for clarity of illustration. Inthis example, the automated machine 128 is configured to move thegripper 108 relative to the operation cell 106 and the fixture tool 102in at least one dimension of the fixed coordinate system 112. In otherwords, at least a portion of the range of motion, or one or more degreesof freedom, of the articulation mechanism 230 is provided by theautomated machine 128.

Referring to FIG. 5 , in an example, the articulation mechanism 230 isseparate from and is independent of the automated machine 128. In thisexample, a full range of motion, or every degree of freedom, of thegripper 108 is provided by (e.g., is inherent to) the articulationmechanism 230.

Referring to FIG. 6 , in another example of the indexing apparatus 100,the interfacing device 220 (FIG. 1 ) includes more than one gripper 108(referred to herein as a plurality of grippers 108). In this example,the indexing apparatus 100 includes more than one indexing feature 104(referred to herein as a plurality of indexing features 104). Each oneof the indexing features 104 is fixed relative to the fixture tool 102.Each one of the grippers 108 is configured to engage and to locate acorresponding one of the indexing features 104.

Referring to FIGS. 1-6 , the indexing apparatus 100 also includes thecontroller 110. The controller 110 is in communication with the gripper108. The controller 110 is configured to locate the fixture tool 102relative to the operation cell 106 (e.g., relative to the referenceframe 216) from the gripper location 114 of the gripper 108, with thegripper 108 engaged to the indexing feature 104.

In an example, the controller 110 is configured to determine the gripperlocation 114 of the gripper 108, for example, relative to the referenceframe 216 in at least one dimension of the fixed coordinate system 112.The controller 110 is also configured to determine the indexing-featurelocation 116 of the indexing feature 104, for example, relative to thereference frame 216 in the at least one dimension of the fixedcoordinate system 112, from the gripper location 114 of the gripper 108.The controller 110 is further configured to determine the fixture-toollocation 118 of the fixture tool 102, for example, relative to thereference frame 216 in the at least one dimension of the fixedcoordinate system 112, from the indexing-feature location 116 of theindexing feature 104.

In an example, the controller 110 is configured to register the digitalmodel 120 (FIG. 1 ), representing the fixture tool 102 and the indexingfeature 104, to the indexing-feature location 116 of the indexingfeature 104. The controller 110 is also configured to convert the modellocation 126 of the digital model 120, registered to theindexing-feature location 116, to the fixture-tool location 118 of thefixture tool 102.

FIG. 7 schematically illustrates an example of inputs 234 provided tothe controller 110 and outputs 236 generated by the controller 110during the locating and indexing operation. In an example,gripper-location data 238 is provided to the controller 110 by thegripper 108. The gripper-location data 238 is an example of theinterface data 222 (FIG. 1 ). In an example, the gripper-location data238 is generated by encoders, sensors, other relative positioningdevices, or a combination thereof and is representative of the actual,physical location of the gripper 108 (the gripper location 114) (FIG. 3), relative to the reference frame 216. The controller 110 processes thegripper-location data 238 and determines the gripper location 114 basedon the gripper-location data 238. The controller 110 then processes thegripper location 114 and determines the indexing-feature location 116based on the gripper location 114.

Referring to FIGS. 2-6 , in an example, with the gripper 108 (e.g., thegrip head 232) engaged to the indexing feature 104, there is at leastone point of contact between the gripper 108 and the indexing feature104. This point of contact has an XYZ-coordinate that is common to boththe gripper 108 and the indexing feature 104. The gripper-location data238 (FIG. 16 ) represents an XYZ-coordinate of the point of contact ofthe gripper 108 and the gripper location 114 is described by theXYZ-coordinate of the point of contact of the gripper 108. Thecontroller 110 converts the XYZ-coordinate of the point of contact ofthe gripper 108 to an XYZ-coordinate of a corresponding point of contactof the indexing feature 104. The controller 110 then determines theindexing-feature location 116 as described by the XYZ-coordinate ofpoint of contact of the indexing feature 104.

In an example, the gripper 108 (e.g., the grip head 232) and theindexing feature 104 include a plurality of points of contact. Thus, thegripper location 114 is described by the XYZ-coordinates of theplurality of points of contact of the gripper 108 and theindexing-feature location 116 is described by the XYZ-coordinates of thecorresponding plurality of points of contact of the indexing feature104.

It should be noted that increasing the number of points of contactbetween the gripper 108 and the indexing feature 104 provides a greaternumber of XYZ-coordinate data points for processing, which, in turn,increases the accuracy of the indexing-feature location 116 and thefixture-tool location 118 during data point alignment of the indexingoperation. In an example, the gripper 108 (e.g., the grip head 232) andthe indexing feature 104 include at least three points of contact.

Referring briefly to FIGS. 8A, 8B, 9A, and 9B, in an example, thegripper 108 (e.g., the grip head 232) includes at least onecontact-index 148 (FIGS. 8A and 9A) and the indexing feature 104includes at least one interface-index 146 (FIGS. 8B and 9B). With thegripper 108 (e.g., the grip head 232) engaged to the indexing feature104, the contact-index 148 engages the interface-index 146 so that thereis at least one point of contact between the contact-index 148 and theinterface-index 146. This point of contact has an XYZ-coordinate that iscommon to both the contact-index 148 and the interface-index 146. Thegripper-location data 238 represents an XYZ-coordinate of the point ofcontact of the contact-index 148 and the gripper location 114 isdescribed by the XYZ-coordinate of the point of contact of thecontact-index 148.

The controller 110 converts the XYZ-coordinate of the point of contactof the contact-index 148 to an XYZ-coordinate of a corresponding pointof contact of the interface-index 146. The controller 110 determines theindexing-feature location 116 as described by the XYZ-coordinate ofpoint of contact of the interface-index 146.

Generally, the gripper 108 (e.g., the grip head 232) includes aplurality of contact-indexes 148 and the indexing feature 104 includes aplurality of interface-indexes 146, which, in turn, provides a pluralityof points of contact. Accordingly, the gripper-location data 238 (FIG. 7) represents the XYZ-coordinates of the plurality of points of contactof the contact-indexes 148 of the gripper 108. The gripper location 114is described by the XYZ-coordinates of the points of contact of thecontact-indexes 148 of the gripper 108. The indexing-feature location116 is described by the XYZ-coordinates of the corresponding pluralityof points of contact of the interface-indexes 146.

In an example, the gripper 108 (e.g., the grip head 232) includes atleast three contact-indexes 148 and the indexing feature 104 include atleast three interface-indexes 146, which result in at least three pointsof contact. In other examples, the gripper 108 (e.g., the grip head 232)may include a lesser number or a greater number of contact-indexes 148and the indexing feature 104 may include a lesser number or a greaternumber of interface-indexes 146.

It should be noted that increasing the number of contact-indexes 148 andinterface-indexes 146 increases the number of points of contact betweenthe gripper 108 and the indexing feature 104, which in turn provides agreater number of XYZ-coordinate data points for processing, which, inturn, increases the accuracy of the indexing-feature location 116 andthe fixture-tool location 118 during data point alignment of theindexing operation.

Referring again to FIG. 7 , the controller 110 is configured to registerthe digital model 120, representing the fixture tool 102 and theindexing feature 104, to the indexing-feature location 116 anddetermines the model location 126. In an example, the controller 110 isconfigured to overlay and align the digital model 120 with theXYZ-coordinates describing the indexing-feature location 116 within thereference frame 216. The digital model 120 includes data pointsrepresenting the points of contact of the indexing feature 104. Forexample, the digital model 120 includes data points that represent theinterface-indexes 146 of the indexing feature 104. In an example, thecontroller 110 performs a best fit operation (e.g., executes a best fitalgorithm) to align data points representing the points of contact ofthe indexing feature 104, such as the data points representing theinterface-indexes 146, with data points representing the XYZ-coordinatesdescribing the indexing-feature location 116. In an example, the bestfit operation includes a rigid body, point cloud transformationoperation.

With the digital model 120 registered and aligned with theindexing-feature location 116, the controller 110 is configured toconvert the model location 126 to the fixture-tool location 118 of thefixture tool 102, for example, relative to the reference frame 216. Forexample, the fixture-tool location 118 is assumed to be the same as themodel location 126 within tolerance. Thus, the fixture-tool location 118represents the immediate (e.g., current, real-time) location of thefixture tool 102 and, thus, the workpiece 170 relative to the operationcell 106 and the automated machine 128.

With the fixture-tool location 118 known, the automated machine 128 isindexed, or is “zeroed”, relative to the fixture-tool location 118 andfollows the predetermined tool path to perform the manufacturingoperation on the workpiece 170. Indexing the automated machine 128relative to the fixture tool 102, based on the fixture-tool location118, consequently indexes the automated machine 128 relative to theworkpiece 170. The geometry of the workpiece 170 and the known locationof the workpiece 170 relative to the fixture tool 102 are incorporatedin and are accounted for by the programmed tool path of the automatedmachine 128.

Referring to FIGS. 1 and 2 , in an example, the indexing apparatus 100includes the automated machine 128. The automated machine 128 is locatedin the operation cell 106 and is in communication with the controller110. The controller 110 is configured to index the automated machine 128relative to the fixture-tool location 118 of the fixture tool 102.

Referring to FIGS. 2 and 4-6 , in an example, the automated machine 128includes a gantry 134. The gantry 134 is configured to provide at leasta portion of the range of motion of, or one or more degrees of freedomto, the automated machine 128. In an example, the robotic arm 226 iscoupled to the gantry 134. In an example, the gantry 134 is an overheadgantry that is movable within the operation cell 106 to move the roboticarm 226 in at least one dimension of the fixed coordinate system 112. Inthis example, the fixture tool 102 and, thus, the workpiece 170 aremoved to the work location 258 within the operation cell 106 and thegantry 134 and/or the robotic arm 226 moves relative to the fixture tool102 so that the end effector 228 follows along the predetermined toolpath.

In another example (not shown), the robotic arm 226 is a stand-alonerobot that has a fixed base within the operation cell 106. In thisexample, the fixture tool 102 and, thus, the workpiece 170 are moved tothe work location 258 within the operation cell 106 and the robotic arm226 moves relative to the fixture tool 102 so that the end effector 228follows along the predetermined tool path.

While the illustrated examples of the indexing apparatus 100 show onlyone automated machine 128 (e.g., one robotic arm 226 with one endeffector 228) for performing the manufacturing operation on theworkpiece 170 in the operation cell 106, in other examples, the indexingapparatus 100 may have any number of additional automated machines 128(e.g., additional robotic arms 226 and/or additional end effectors 228).

Referring to FIGS. 1 and 2 , in an example, the manufacturing operationincludes a pre-cure composite assembly operation or other additivemanufacturing operation performed on a pre-cure composite material, suchas a composite layup operation and/or a composite lamination operation.In this example, the workpiece 170 includes a pre-cure compositelaminate (e.g., layup of a pre-impregnated composite material). Thefixture tool 102 includes, or takes the form of, a mandrel 130. Themandrel 130 is configured to support the composite laminate (theworkpiece 170). The automated machine 128 is configured to perform apre-cure manufacturing operation on the composite laminate (theworkpiece 170). For example, the automated machine 128 includes, ortakes the form of, an automated fiber placement machine 132 (FIG. 1 ).

In one or more other examples, the manufacturing operation includesother additive manufacturing operation, such as an assembly operation,or subtractive manufacturing operation, such as a machining operation.In such examples, the workpiece 170 is one of a post-cure compositestructure, a metallic structure, a plastic structure, or othernon-composite structure. The fixture tool 102 includes at least oneholding-feature 260 (FIG. 1 ) that is configured to secure the workpiece170 to the fixture tool 102, during movement to the operation cell 106and during the manufacturing operation. The automated machine 128 isconfigured to perform at least one of an additive manufacturingoperation and a subtractive manufacturing operation on the workpiece170. In an example, the automated machine 128 is configured to perform apost-cure manufacturing operation on the post-cure composite structure.For example, the automated machine 128 includes, or takes the form of,any appropriate machine tool 270 (FIG. 1 ).

In one or more examples, any one of the various manufacturing operationsdescribed herein is part of a continuous flow manufacturing process. Forexample, the fixture tool 102 and the workpiece 170 are pulsed to one ofa plurality of operation cells forming a continuous flow manufacturingsystem. At any given one of the plurality of operation cells, themanufacturing operation forms a portion of the continuous flowmanufacturing process. In an example, the manufacturing operationincludes placing one or more plies of a pre-cure composite material topartially form the composite laminate. In an example, the manufacturingoperation includes assembly or installation of a secondary structure tothe post-cure composite structure or the non-composite structure. In anexample, the manufacturing operation includes machining one or morefeatures in the post-cure composite structure or the non-compositestructure.

In an example, the fixture tool 102 is moved into the work location 258and the immediate location of the fixture tool 102 and the workpiece 170(e.g., the fixture-tool location 118) is determined using the gripper108 and the indexing feature 104, as described above. Based on thefixture-tool location 118 (e.g., the location of the fixture tool 102and the location of the workpiece 170 relative to the fixture tool 102),the automated fiber placement machine 132 lays down and/or consolidatesat least a portion of at least one layer of a stack of composite sheets.

Referring to FIGS. 2 and 4-6 , in an example, the indexing apparatus 100includes a drive assembly 138 that is coupled to the gripper 108. Thedrive assembly 138 is configured to move the gripper 108 relative to thereference frame 216, such as in at least one dimension of the fixedcoordinate system 112. In an example, the drive assembly 138 is coupledto, or forms a portion of, the articulation mechanism 230 of the gripper108, such as in examples where the gripper 108 is separate from theautomated machine 128, as illustrated in FIGS. 5 and 6 . In anotherexample, the drive assembly 138 is couple to, or is formed by, theautomated machine 128, such as in examples where the gripper 108 iscoupled to the automated machine 128, as illustrated in FIGS. 2 and 4 .

Referring to FIG. 1 , in an example, the gripper 108 is configured tomove the fixture tool 102 inside of the work envelope 140 of theoperation cell 106. In an example, the fixture tool 102 and theworkpiece 170 are moved to an initial, pre-work location, for example, alocation that is proximate to (e.g., at or near) the work location 258(e.g., outside of the operation cell 106). The gripper 108, operatingunder computer control, moves into engagement with the indexing feature104. While engaged to the indexing feature 104, the gripper 108 movesthe fixture tool 102 and the workpiece 170 to the work location 258(e.g., inside the operation cell 106). In this manner, the fixture tool102 and the workpiece 170 are moved to the work location 258 while thefixture-tool location 118 is being determined, as described above. Thiscombined operation further improves the cycle time of the manufacturingoperation by enabling the moving operation of the fixture tool 102 andthe workpiece 170 and the locating operation of the fixture tool 102 andthe workpiece 170 to be performed substantially concurrently.

In another example, the indexing apparatus 100 includes an independentmoving mechanism (not shown) that is separate from the gripper 108 andthat is configured to move the fixture tool 102 to the work location258. In this example, the fixture tool 102 and the workpiece 170 aremoved to the pre-work location and the independent moving mechanism,operating under computer control, moves the fixture tool 102 and theworkpiece 170 to the work location 258.

FIGS. 8A, 8B, 9A and 9B schematically illustrate examples of the gripper108 and the indexing feature 104. In an example, the gripper 108 (e.g.,the grip head 232) includes a jaw assembly 144 (FIGS. 8A and 9A). Thejaw assembly 144 is configured to grip, grasp, clamp, or otherwisesecurely hold at least a portion of the indexing feature 104 (FIGS. 8Band 9B). In an example, the indexing feature 104 includes a plate 150that is coupled to and extends from the fixture tool 102 (not shown inFIG. 8B). The contact-index 148 (FIGS. 8A and 9A) and theinterface-index 146 (FIGS. 8B and 9B) are configured to contact and matewith each other when the gripper 108 (e.g., the jaw assembly 144)properly engages the indexing feature 104 (e.g., the plate 150).

Referring to FIGS. 8A and 8B, in an example, the jaw assembly 144 isincludes a first jaw and a second jaw. The first jaw and the second jaware movable relative to each another to selectively engage (e.g., grip)the plate 150. In an example, the jaw assembly 144 includes a first(e.g., upper) jaw that is stationary and a second (e.g., lower) jaw thatis movable relative to the first jaw. In an example, each jaw of the jawassembly 144 has an approximately planar engaging surface that isconfigured to make secure contact with a corresponding one of opposingplanar engaging surfaces of the plate 150. Other configurations of thejaw assembly 144 and the plate 150 are also contemplated.

In an example, the contact-index 148 (FIG. 8A) is coupled to, or isdisposed on, the jaw assembly 144 and the interface-index 146 (FIG. 8B)is coupled to, or is disposed on, the plate 150. The contact-index 148is suitably located and is configured to engage the interface-index 146when the jaw assembly 144 grips the plate 150. In an example, thecontact-index 148 is located on and projects from the engaging surfaceof one of the jaws (e.g., the upper jaw) of the jaw assembly 144 and theinterface-index 146 is located on and projects from one of the engagingsurfaces of the plate 150.

In an example, the contact-index 148 includes, or takes the form of, atleast one contacting-structure 154. The interface-index 146 includes, ortakes the form of, at least one interfacing-structure 152. In anexample, the interfacing-structure 152 and the contacting-structure 154have complementary geometric shapes and dimensions so that correspondingsurfaces of the contacting-structure 154 (e.g., forming thecontact-index 148) and interfacing-structure 152 (e.g., forming theinterface-index 146) are in contact when the grip head 232 properlyengages the indexing feature 104. Each one of the contacting-structure154 and the interfacing-structure 152 includes, or takes the form of,any one of various structural configurations or arrangements.

In an example, the contacting-structures 154 and theinterfacing-structures 152 include, or take the form of, a plurality ofcooperating and complementary point structures. In the illustratedexample, the contacting-structure 154 includes, or takes the form of, aprotrusion formed on (e.g., projecting from) a surface of the grip head232 and the interfacing-structure 152 includes, or takes the form, of anaperture formed in (e.g., depending from) a surface of the plate 150. Inthis example, the interfacing-structure 152 is configured to receive andmate with at least a portion of the contacting-structure 154. In anotherexample, this arrangement may be reversed. For example, thecontacting-structure 154 includes, or takes the form of, the apertureand the interfacing-structure 152 includes, or takes the form of, theprotrusion. As examples, the protrusion may be, or may take the form of,a pin, a spring-loaded ball bearing, or other protruding body and theaperture may be, or may take the form of, a hole, a detent, a recess, orother opening.

Referring to FIGS. 9A and 9B, in another example, theinterfacing-structure 152 of the interface-index 146 includes, or takesthe form of, a tooling ball that projects from the plate 150. Thecontacting-structure 154 of the contact-index 148 includes, or takes theform of, a cooperating tooling hole that is formed by the jaw assembly144 and that is configured to receive and mate with the tooling ballwhen the grip head 232 properly engages the plate 150. In anotherexample, this arrangement may be reversed. For example, thecontacting-structure 154 includes, or takes the form of, the toolingball and the interfacing-structure 152 includes, or takes the form of,the tooling hole.

Other structural configurations and/or arrangements of the contact-index148 (e.g., the contacting-structure 154) and the interface-index 146(e.g., the interfacing-structure 152) are also contemplated, such as acooperating and complementary cup and cone configuration and the like.

Generally, any suitable configuration or arrangement of thecontact-index 148 and the interface-index 146 may be used such thatthere are at least three points of contact between the gripper 108 andthe indexing feature 104 that can be used to generate at least threedata points representing at least three XYZ-coordinates of the indexingfeature 104. In most cases, three data points is sufficient to generatea complete three-dimensional location of the fixture tool 102, duringthe locating and indexing operation described above.

In an example, the XZY-coordinate locations of at least two of thecontact-indexes 148 (e.g., at least two of the contacting-structures154) are different in at least two dimensions of the fixed coordinatesystem 112. Similarly, the XZY-coordinate locations of at least two ofthe interface-indexes 146 (e.g., at least two of theinterfacing-structures 152) are different in at least two dimensions ofthe fixed coordinate system 112.

In an example implementation of the locating and indexing operationdescribed above, the fixture tool 102 and, thus, the workpiece 170 aremoved into the work location 258 for engagement of the indexing feature104 by the gripper 108. With the fixture tool 102 in the work location258, the location of the indexing feature 104 relative to the referenceframe 216 is approximately known or is estimated within an acceptabletolerance to enable the gripper 108 to move to a pre-engaged locationrelative to the indexing feature 104, under computer control. Thecontroller 110 then executes a search operation in which the gripper 108incrementally moves along a predefined search path to find theinterface-index 146 and to align and mate the contact-index 148 and theinterface-index 146. With the contact-index 148 and the interface-index146 suitably aligned and mated with each other, the contact-index 148and the interface-index 146 share the point of contact and the locatingand indexing operation is performed as described above.

Referring to FIGS. 8A and 9A, in an example, the gripper 108 includes atleast one engagement-sensor 240. The engagement-sensor 240 is configuredto determine when the gripper 108 is properly aligned with and engagedto the indexing feature 104, such as when the contact-index 148 and theinterface-index 146 are suitably aligned and mated with each other. Theengagement-sensor 240 includes, or takes the form of, any one of varioustypes of suitable sensors, such as a depth gauge, a pressure sensor, atooling probe, a displacement sensor, and the like.

Referring to FIGS. 1-6 , in an example, the indexing apparatus 100includes a vehicle 160. The vehicle 160 is configured to support thefixture tool 102. The vehicle 160 is also configured to move the fixturetool 102 relative to the operation cell 106. In an example, the vehicle160 is configured to move the fixture tool 102 and, thus, the workpiece170 to the work location 258 at which the gripper 108 engages theindexing feature 104 to perform the locating and indexing operationsdescribed above. In another example, the vehicle 160 is configured tomove the fixture tool 102 and, thus, the workpiece 170 to the pre-worklocation relative to the operation cell 106 at which the gripper 108engages the indexing feature 104 to perform the moving, locating, andindexing operations described above.

Referring to FIG. 1 , in an example, the vehicle 160 includes, or takesthe form of, an automated guided vehicle 162. The automated guidedvehicle 162 is configured to autonomously move along a predefined travelpath under computer control. In this example, the operation cell 106 mayinclude one or more of sensors, guide tape, guide wires, laser targets,and any other suitable navigation mechanisms for moving the automatedguided vehicle 162 along the predefined travel path. In this example,the automated guided vehicle 162 moving along the predefined travel pathis configured to move the fixture tool 102 into the work location 258(or the pre-work location) for the gripper 108 to find and engage theindexing feature 104, as described above.

Referring to FIGS. 1 and 2 , in an example, the vehicle 160 includes, ortakes the form of a cart 164. The cart 164 is configured to travel alonga track 166 running through the operation cell 106. In this example, thecart 164 moving along the track 166 is configured to move the fixturetool 102 into the work location 258 (or the pre-work location) for thegripper 108 to find and engage the indexing feature 104, as describedabove.

In an example, the track 166 is arranged such that the Z-coordinate ofthe fixture tool 102 and, thus, the indexing feature 104 is fixed andremains constant as the cart 164 travels along the track 166 to the worklocation 258. In this example, the locating operation performed by thegripper 108 needs only to determine the XY-coordinate of the points ofcontact between the gripper 108 and the indexing feature 104.

Referring to FIGS. 1 and 2 , in an example, the manufacturing system 168includes the operation cell 106 and the automated machine 128. Theautomated machine 128 is located in the operation cell 106 and isconfigured to perform at least one manufacturing operation. Themanufacturing system 168 also includes the fixture tool 102. The fixturetool 102 is configured to support the workpiece 170 and is movablerelative to the operation cell 106. The manufacturing system 168 furtherincludes the indexing feature 104. The indexing feature 104 is fixedrelative to the fixture tool 102. For example, the indexing feature 104is coupled to the fixture tool 102.

The manufacturing system 168 also includes the gripper 108. The gripper108 is configured to engage the indexing feature 104. The manufacturingsystem 168 further includes the controller 110. The controller 110 is incommunication with the gripper 108 and the automated machine 128. Thecontroller 110 is configured to locate the fixture tool 102 relative tothe operation cell 106 from the gripper location 114 of the gripper 108,engaged with the indexing feature 104. The controller 110 is alsoconfigured to index the automated machine 128 relative to thefixture-tool location 118 of the fixture tool 102.

Referring to FIGS. 1 and 7 , in an example of the manufacturing system168, the controller 110 is configured to determine the gripper location114 of the gripper 108 in at least one dimension of the fixed coordinatesystem 112. The controller 110 is also configured to determine theindexing-feature location 116 of the indexing feature 104 in the atleast one dimension of the fixed coordinate system 112 from the gripperlocation 114 of the gripper 108. The controller 110 is furtherconfigured to determine the fixture-tool location 118 of the fixturetool 102 in the at least one dimension of the fixed coordinate system112 from the indexing-feature location 116 of the indexing feature 104.The controller 110 is also configured to register the digital model 120,representing the fixture tool 102 and the indexing feature 104, to theindexing-feature location 116 of the indexing feature 104 and to convertthe model location 126 of the digital model 120, registered to theindexing-feature location 116, to the fixture-tool location 118 of thefixture tool 102.

Referring to FIGS. 1-3 , in an example of the manufacturing system 168,the fixture tool 102 includes the mandrel 130 that is configured tosupport a composite laminate and the automated machine 128 includes theautomated fiber placement machine 132 that is configured to perform atleast one composite lay-up or lamination operation.

Referring to FIGS. 2 and 4 , in an example of the manufacturing system168, the gripper 108 is coupled to the automated machine 128 and theautomated machine 128 is configured to move the gripper 108 relative tothe reference frame 216 in at least one dimension of the fixedcoordinate system 112. Referring to FIGS. 5 and 6 , in an example, thegripper 108 is configured to move independent of the automated machine128. Referring to FIGS. 2-6 , in an example, the gripper 108 isconfigured to move the fixture tool 102 inside of the work envelope 140of the operation cell 106.

Referring to FIGS. 8A, 8B, 9A and 9B, in an example of the manufacturingsystem 168, the indexing feature 104 includes at least oneinterface-index 146. The gripper 108 includes at least one contact-index148 that is configured to engage the at least one interface-index 146.

Referring to FIG. 1-6 , in an example, the manufacturing system 168includes the vehicle 160. The vehicle 160 is configured to support thefixture tool 102 and to move the fixture tool 102 relative to theoperation cell 106.

Referring to FIGS. 1 and 2 , in an example, the manufacturing system 168also includes the track 166. The track 166 runs through the operationcell 106. In this example, the vehicle 160 includes, or takes the formof, the cart 164 that is configured to travel along the track 166.

Referring to FIG. 10 , in an example, the manufacturing system 168includes the second operation cell 172. The manufacturing system 168also includes the second automated machine 174. The second automatedmachine 174 is located in the second operation cell 172 and isconfigured to perform at least one manufacturing operation on theworkpiece 170.

The manufacturing system 168 further includes a second gripper 176. Thesecond gripper 176 is configured to engage the indexing feature 104. Thecontroller 110 is in communication with the second gripper 176 and thesecond automated machine 174. The controller 110 is configured to locatethe fixture tool 102 relative to the second operation cell 172 from asecond gripper-location 178 of the second gripper 176, engaged with theindexing feature 104. The controller 110 is further configured to indexthe second automated machine 174 relative to a second fixture-toollocation 180 of the fixture tool 102. Once indexed, the second automatedmachine 174 performs at least one manufacturing operation on theworkpiece 170.

Referring generally to FIG. 1 and particularly to FIGS. 11-13 , inanother example, the indexing apparatus 100 includes the fixture tool102. The fixture tool 102 is movable relative to the operation cell 106.The apparatus 100 also includes the indexing feature 104. The indexingfeature 104 is fixed relative to the fixture tool 102. For example, theindexing feature 104 is located on the fixture tool 102.

In the examples illustrated in FIGS. 11-15 , the indexing feature 104 iscoupled to, or is located on, a top of the fixture tool 102. In otherexamples, the indexing feature 104 is coupled to, or is located on,another portion (e.g., a side, a front, a rear, a bottom, etc.) of thefixture tool 102.

In an example, the indexing apparatus 100 includes the sensor 184. Thesensor 184 is configured to detect (e.g., visually identify) theindexing feature 104. The indexing feature 104 is appropriately locatedrelative to the fixture tool 102 so that at least a portion of theindexing feature 104 is visually accessible by the sensor 184.Conversely, the sensor 184 is appropriately located relative to thefixture tool 102 so that at least a portion of the sensor 184 isphysically accessible by the indexing feature 104. In an example, theindexing feature 104 is located on, or is formed in, an exposed, outersurface of the fixture tool 102. The sensor 184 is configured togenerate sensor data 186 (FIG. 1 ) that is representative of thelocation of the indexing feature 104 (the indexing-feature location 116)(FIG. 1 ). In other words, the sensor 184 locates the indexing feature104 in the reference frame 216.

Referring to FIGS. 11-13 , in an example, the sensor 184 includes thearticulation mechanism 230 and a sensor head 242 that is coupled to theworking end of the articulation mechanism 230. The articulationmechanism 230 is configured to move the sensor head 242 inthree-dimensional space, such as linearly along at least one axis of thefixed coordinate system 112 and/or rotationally about at least one axisof the fixed coordinate system 112.

The articulation mechanism 230 is also configured to provide locationdata (e.g., interface data 222) (FIG. 1 ) that represents a location ofthe sensor 184 (e.g., the sensor head 242) relative to the referenceframe 216. In an example, the location data and the sensor data 186 areused to determine the indexing-feature location 116 relative to thereference frame 216. In an example, and for the purpose of the presentdescription, the location data of the sensor 184 relative to thereference frame 216 is incorporated with the sensor data 186.

Referring to FIG. 13 , the sensor head 242 includes, or takes the formof, any one of various machine vision or computer vision systems that isconfigured to scan the fixture tool 102 and identify the indexingfeature 104 from the scan. In an example, the sensor 184 (e.g., thesensor head 242) includes, or takes the form of, a camera that isconfigured to capture still images or video (e.g., the sensor data 186)that visually represent the fixture tool 102 and the indexing feature104. In another example, the sensor 184 (e.g., the sensor head 242)includes, or takes the form of, a laser scanner that is configured toproject laser light onto the fixture tool 102 and collect laser lightdeflected back from the fixture tool 102 and to generate the sensor data186 from the collected laser light that represents the indexing feature104.

In an example, the sensor data 186 is representative of, or correspondsto, the indexing-feature location 116. In an example, the laser scanneris a two-dimensional laser scanner and the sensor data 186 isrepresentative of the location of the indexing feature 104 in twodimensions of the fixed coordinate system (e.g., the XY-coordinates). Inanother example, the laser scanner is a three-dimensional laser scannerand the sensor data 186 is representative of the location of theindexing feature in three dimensions of the fixed coordinate system(e.g., the XYZ-coordinates).

Referring to FIGS. 11 and 12 , in an example, the articulation mechanism230 is coupled to, or forms a portion of, the automated machine 128. InFIG. 12 , the robotic arm 226 and the end effector 228 (FIG. 11 ) of theautomated machine 128 (e.g., for performing the at least onemanufacturing operation) are removed for clarity of illustration. Inthis example, the automated machine 128 is configured to move the sensor184 relative to the operation cell 106 and the fixture tool 102 in atleast one dimension of the fixed coordinate system 112. In other words,at least a portion of the range of motion, or one or more degrees offreedom, of the articulation mechanism 230 is provided by the automatedmachine 128.

Referring to FIG. 13 , in an example, the articulation mechanism 230 isseparate from and is independent of the automated machine 128. In thisexample, a full range of motion, or every degree of freedom, of thesensor 184 is provided by (e.g., is inherent to) the articulationmechanism 230.

Referring to FIG. 14 , in another example of the indexing apparatus 100,the interfacing device 220 (FIG. 1 ) includes more than one sensor 184(referred to herein as a plurality of sensors 184). In this example, theindexing apparatus 100 includes more than one indexing feature 104(e.g., the plurality of indexing features 104). Each one of the indexingfeatures 104 is fixed relative to the fixture tool 102. Each one ofsensors 184 is configured to scan, detect, and locate at least a portionof the indexing feature 104 or a corresponding one of a plurality of theindexing features 104.

Referring to FIGS. 1 and 11-15 , the indexing apparatus 100 alsoincludes the controller 110. The controller 110 is in communication withthe sensor 184. The controller 110 is configured to locate the fixturetool 102 relative to the operation cell 106 from the indexing-featurelocation 116 of the indexing feature 104, identified by the sensor 184.

In an example, the controller 110 is configured to determine theindexing-feature location 116 of the indexing feature 104, for example,relative to the reference frame 216 in at least one dimension of thefixed coordinate system 112, from the sensor data 186, generated by thesensor 184. The controller 110 is also configured to determine thefixture-tool location 118 of the fixture tool 102, for example, relativeto the reference frame 216 in the at least one dimension of the fixedcoordinate system 112, from the indexing-feature location 116 of theindexing feature 104.

In an example, the controller 110 is configured to register the digitalmodel 120 (FIG. 1 ), representing the fixture tool 102 and the indexingfeature 104, to the indexing-feature location 116 of the indexingfeature 104. The controller 110 is also configured to convert the modellocation 126 of the digital model 120, registered to theindexing-feature location 116, to the fixture-tool location 118 of thefixture tool 102.

FIG. 16 schematically illustrates an example of the inputs 234 providedto the controller 110 and the outputs 236 generated by the controller110 during the locating and indexing operation. In an example, thesensor data 186 is provided to the controller 110 from the sensor 184.The sensor data 186 is an example of the interface data 222 (FIG. 1 ).In an example, the sensor data 186 (e.g., the interface data 222) alsoincludes the location data that is representative of the actual,physical location of the sensor 184 (e.g., the sensor head 242) (FIG. 13) relative to the reference frame 216, for example, as generated byencoders, sensors, other relative positioning devices, or a combinationthereof. The controller 110 processes the sensor data 186 and determinesthe indexing-feature location 116, based on the sensor data 186.

Referring to FIGS. 11-15 , in an example, the sensor 184 (e.g., thesensor head 242) moves along a scan path relative to the fixture tool102 and scans at least a portion of the fixture tool 102 that includesthe indexing feature 104. The sensor 184 may collect a sufficient amountof data points of the sensor data 186 (FIG. 16 ) to locate the indexingfeature 104 in a single pass or may require more than one pass. Thecontroller 110 is configured to identify and extract data pointsrepresenting the indexing feature 104. The controller 110 thendetermines the XYZ-coordinates of the data points representing theindexing feature 104 relative to the reference frame 216. The controller110 then determines the indexing-feature location 116 as described bythe XYZ-coordinates of the data points representing the indexing feature104 in the sensor data 186.

The indexing feature 104 includes a structure that is visuallyperceptible and/or computationally distinguishable from a surroundingsurface area of the fixture tool 102. For example, the indexing feature104 includes a structural configuration that is suitable forcomputational perception and recognition, such as in a point cloudprocessing operation performed on a plurality of data points of thesensor data 186. The indexing-feature location 116 is described by theXYZ-coordinates of the plurality of data points representing theindexing feature 104 in the sensor data 186.

It should be noted that increasing the number of data pointsrepresenting the indexing feature 104 in the sensor data 186 provides agreater number of XYZ-coordinate data points for processing, which, inturn, increases the accuracy of the indexing-feature location 116 andthe fixture-tool location 118 during data point alignment of theindexing operation.

The controller 110 is configured to register the digital model 120,representing the fixture tool 102 and the indexing feature 104, to theindexing-feature location 116 and determines the model location 126. Inan example, the controller 110 is configured to overlay and align thedigital model 120 with the XYZ-coordinates describing theindexing-feature location 116 within the reference frame 216. Thedigital model 120 includes data points representing the indexing feature104. In an example, the controller 110 performs a best fit operation(e.g., executes a best fit algorithm) to align data points representingthe indexing feature 104 with data points representing theXYZ-coordinates describing the indexing-feature location 116. In anexample, the best fit operation includes a rigid body, point cloudtransformation operation.

With the digital model 120 registered and aligned with theindexing-feature location 116, the controller 110 is configured toconvert the model location 126 to the fixture-tool location 118 of thefixture tool 102, for example, relative to the reference frame 216. Forexample, the fixture-tool location 118 is assumed to be the same as themodel location 126 within tolerance. Thus, the fixture-tool location 118represents the immediate (e.g., current, real-time) location of thefixture tool 102 and, thus, the workpiece 170 relative to the operationcell 106 and the automated machine 128.

With the fixture-tool location 118 known, the automated machine 128 isindexed, or is “zeroed”, relative to the fixture-tool location 118 andfollows the predetermined tool path to perform the manufacturingoperation on the workpiece 170. Indexing the automated machine 128relative to the fixture tool 102, based on the fixture-tool location118, consequently indexes the automated machine 128 relative to theworkpiece 170. The geometry of the workpiece 170 and the known locationof the workpiece 170 relative to the fixture tool 102 are incorporatedin and are accounted for by the programmed tool path of the automatedmachine 128

Referring to FIGS. 1 and 11 , in an example, the indexing apparatus 100includes the automated machine 128. The automated machine 128 is locatedin the operation cell 106 and is in communication with the controller110. The controller 110 is configured to index the automated machine 128relative to the fixture-tool location 118 of the fixture tool 102.

Referring to FIGS. 11, 12, 14 and 15 , in an example, the automatedmachine 128 includes the gantry 134. In this example, the fixture tool102 and, thus, the workpiece 170 is moved to the work location 258within the operation cell 106 and the gantry 134 and/or the robotic arm226, coupled to the gantry 134, moves relative to the fixture tool 102so that the end effector 228 follows along the predetermined tool path.

In another example (not shown), the robotic arm 226 is a stand-alonerobot that has a fixed base within the operation cell 106. In thisexample, the fixture tool 102 and, thus, the workpiece 170 are moved tothe work location 258 within the operation cell 106 and the robotic arm226 moves relative to the fixture tool 102 so that the end effector 228follows along the predetermined tool path.

While the illustrated examples of the indexing apparatus 100 show onlyone automated machine 128 (e.g., one robotic arm 226 with one endeffector 228) for performing the manufacturing operation on theworkpiece 170 in the operation cell 106, in other examples, the indexingapparatus 100 may have any number of additional automated machines 128(e.g., additional robotic arms 226 and/or additional end effectors 228).

Referring to FIGS. 1 and 11 , in an example, the manufacturing operationincludes a pre-cure composite assembly operation, such as the compositelayup operation and/or composite lamination operation. In this example,the workpiece 170 includes the composite laminate (e.g., layup of acomposite material). The fixture tool 102 includes, or takes the formof, the mandrel 130. The mandrel 130 is configured to support acomposite laminate. The automated machine 128 includes, or takes theform of, the automated fiber placement machine 132.

In an example, the fixture tool 102 is moved into the work location 258and the immediate location of the fixture tool 102 and the workpiece 170(e.g., the fixture-tool location 118) is determined using the sensor 184and the indexing feature 104, as described above. Based on thefixture-tool location 118 (e.g., the location of the fixture tool 102and the location of the workpiece 170 relative to the location of thefixture tool 102), the automated fiber placement machine 132 lays downand/or consolidates at least a portion of at least one layer of a stackof composite sheets.

In one or more other examples (not explicitly illustrated), themanufacturing operation includes another assembly operation or machiningoperation. In such examples, the workpiece 170 may be a post-curecomposite workpiece, metallic workpiece, plastic workpiece, or othernon-composite workpiece. The fixture tool 102 includes the suitableholding-features 260 (FIG. 1 ) configured to secure the workpiece 170during movement to the operation cell 106 and during the manufacturingoperation. The automated machine 128 includes, or takes the form of, anyappropriate machine tool.

Referring to FIGS. 12, 14 and 15 , in an example, the indexing apparatus100 includes the drive assembly 138 that is coupled to the sensor 184.The drive assembly 138 is configured to move the sensor 184 (e.g., thesensor head 242) relative to the reference frame 216, such as in one ormore dimensions of the fixed coordinate system 112. In an example, thedrive assembly 138 is coupled to, or forms a portion of the articulationmechanism 230 of the sensor 184, such as in examples where the sensor184 is separate from the automated machine 128, as illustrated in FIGS.14 and 15 . In another example, the drive assembly 138 is couple to, oris formed by, the automated machine 128, such as in examples where thesensor 184 is coupled to the automated machine 128, as illustrated inFIGS. 11 and 12 .

In an example, the indexing apparatus 100 includes the independentmoving mechanism (not shown) that is configured to move the fixture tool102 to the work location 258.

Referring to FIG. 13 , in an example, the indexing feature 104 includesat least one interfacing-structure 192. In the example illustrated inFIG. 13 , the indexing feature 104 includes two interfacing-structures192. However, in other examples, the indexing feature 104 includes anynumber of interfacing-structures 192.

In an example, the interfacing-structure 192 is located on a surface 194(e.g., an exposed surface) of the fixture tool 102. In other words, theinterfacing-structure 192 is suitably located as not to be covered orotherwise obscured by the workpiece 170 (not shown in FIG. 13 ) that issecured to the fixture tool 102. The interfacing-structure 192 issuitably located to be visually accessible by the sensor 184 during thelocating and indexing operation described above. Theinterfacing-structure 192 includes any one of a variety of differentstructures that is visually perceptible and/or computationallydiscernable from the surface 194 of the fixture tool 102 that surroundsthe indexing feature 104. FIGS. 17-20 schematically illustrate variousexamples of the interfacing-structure 192.

Referring to FIG. 17 , in an example, in an example of the indexingfeature 104, the interfacing-structure 192 is continuous and extendslongitudinally along the surface 194 (e.g., a top surface) of thefixture tool 102. In other words, the interfacing-structure 192 may be acontinuous interfacing-structure. In an example, theinterfacing-structure 192 may be linear, as illustrated in FIG. 17 . Inanother example, the interfacing-structure 192 may be non-linear.

Referring to FIG. 18 , in another example of the indexing feature 104,the interfacing-structure 192 is discontinuous and extendslongitudinally along the surface 194 of the fixture tool 102. In otherwords, the interfacing-structure 192 may be a plurality of discontinuousinterfacing-point structures (e.g., also referred to herein as aplurality of interfacing-structures 192). In an example, the pluralityof interfacing-structures 192 may be arranged linearly, as illustratedin FIG. 18 . In another example, the plurality of interfacing-structures192 may be arranged non-linearly.

In an example, the interfacing-structure 192 is a continuous grooveformed in (e.g., depending from) the surface 194 of the fixture tool102. In another example, the interfacing-structure 192 is a continuousridge formed on (e.g., projecting from) the surface 194 of the fixturetool 102. In another example, each one of the plurality ofinterfacing-structures 192 includes an aperture formed in (e.g.,depending from) the surface 194. In another example, each one of theplurality of interfacing-structures 192 includes a protrusion formed on(e.g., projecting from) the surface 194.

In the illustrated example, the indexing feature 104 includes twointerfacing-structures 192. In other examples, the indexing feature 104includes any number of interfacing-structures 192. Other structuralconfigurations and/or arrangements of the interfacing-structure 192 arealso contemplated.

Referring to FIG. 19 , in another example, the interfacing-structure 192is formed by an edge of the fixture tool 102. In an example, the edgeextends continuously and longitudinally along the fixture tool 102. Inan example, the edge is formed by the intersection of two exposedsurfaces 194 (e.g., a top surface and a side surface) of the fixturetool 102. In the illustrated example, the interfacing-structure 192 ofthe indexing feature 104 includes, or is formed by, two edges of thefixture tool 102. In other examples, the interfacing-structure 192 ofthe indexing feature 104 includes, or is formed by, any number of edges.

In another example, the interfacing-structure 192 includes a combinationof two or more of types of structures, such as grooves, ridges, a seriesof apertures, a series of protrusions, and edges. Various otherconfigurations of the interfacing-structure 192 are also contemplated.

In an example in which the indexing feature 104 includes two or moreinterfacing-structures 192, the interfacing-structures 192 (e.g.,grooves, ridges, apertures, protrusions, and edges) are non-parallel toeach other (e.g., oriented oblique to each other). The non-parallelarrangement of the interfacing-structures 192 provides non-parallel datapoints in the sensor data 186 that can be combined during processing toderive the XYZ-coordinates of the plurality of data points relative tothe reference frame 216 in more than one dimension of the fixedcoordinate system 112.

Referring to FIGS. 11-15 , in an example, the indexing apparatus 100includes the vehicle 160. The vehicle 160 is configured to support thefixture tool 102 and to move the fixture tool 102 relative to theoperation cell 106. In an example, the vehicle 160 is configured to movethe fixture tool 102 and, thus, the workpiece 170 to the work location258 at which the sensor 184 scans and detects (e.g., visuallyidentifies) the indexing feature 104 to perform the locating andindexing operations described above.

Referring to FIG. 1 , in an example of the indexing apparatus 100, thevehicle 160 includes, or takes the form of, the automated guided vehicle162. Referring to FIGS. 1 and 11 , in an example, the vehicle 160includes, or takes the form of, the cart 164. The cart 164 is configuredto travel along the track 166 running through the operation cell 106.

In an example, the track 166 is arranged such that the Z-coordinate ofthe fixture tool 102 and, thus, the indexing feature 104 is fixed andremains constant as the cart 164 travels along the track 166 to the worklocation 258. In this example, the locating operation performed by thesensor 184 needs only to determine the XY-coordinate of the indexingfeature 104.

Referring to FIGS. 1 and 11 , in another example, the manufacturingsystem 168 includes the operation cell 106 and the automated machine128. The automated machine 128 is located in the operation cell 106 andis configured to perform at least one manufacturing operation. Themanufacturing system 168 also includes the fixture tool 102. The fixturetool 102 is configured to support the workpiece 170 and is movablerelative to the operation cell 106. The manufacturing system 168 furtherincludes the indexing feature 104. The indexing feature 104 is fixedrelative to the fixture tool 102. For example, the indexing feature 104is located on the fixture tool 102.

The manufacturing system 168 also includes the sensor 184. The sensor184 is configured to detect (e.g., visually identify) the indexingfeature 104. The manufacturing system 168 further includes thecontroller 110 that is in communication with the sensor 184 and theautomated machine 128. The controller 110 is configured to locate thefixture tool 102 relative to the operation cell 106 from theindexing-feature location 116 of the indexing feature 104, identified bythe sensor 184. The controller 110 is also configured to index theautomated machine 128 relative to the fixture-tool location 118 of thefixture tool 102.

Referring to FIGS. 1 and 16 , in an example of the manufacturing system168, the controller 110 is configured to determine the indexing-featurelocation 116 of the indexing feature 104 in at least one dimension ofthe fixed coordinate system 112 from sensor data 186, generated by thesensor 184. The controller 110 is also configured to determine thefixture-tool location 118 of the fixture tool 102 in the at least onedimension of the fixed coordinate system 112 from the indexing-featurelocation 116 of the indexing feature 104. The controller 110 is furtherconfigured to register the digital model 120, representing the fixturetool 102 and the indexing feature 104, to the indexing-feature location116 of the indexing feature 104; and to convert the model location 126of the digital model 120, registered to the indexing-feature location116, to the fixture-tool location 118 of the fixture tool 102.

Referring to FIGS. 1, 11 and 13 , in an example of the manufacturingsystem 168, the fixture tool 102 includes the mandrel 130 that isconfigured to support a composite laminate and the automated machine 128includes the automated fiber placement machine 132 that is configured toperform at least one composite lay-up or lamination operation.

Referring to FIGS. 11 and 12 , in an example of the manufacturing system168, the sensor 184 is coupled to the automated machine 128 and theautomated machine 128 is configured to move the sensor 184 relative tothe fixture tool 102 in at least one dimension of the fixed coordinatesystem 112. Referring to FIGS. 14 and 15 , in an example, the sensor 184is configured to move independent of the automated machine 128.

Referring to FIGS. 13 and 17-19 , in an example of the manufacturingsystem 168, the indexing feature 104 includes at least oneinterfacing-structure 192, located on the surface 194 of the fixturetool 102. The interfacing-structure 192 is visually detectable (e.g.,perceptible and recognizable) by the sensor 184.

Referring to FIGS. 1 and 11-15 , in an example, the manufacturing system168 includes the vehicle 160. The vehicle 160 is configured to supportthe fixture tool 102 and to move the fixture tool 102 relative to theoperation cell 106.

Referring to FIGS. 1 and 11 , in an example, the manufacturing system168 also includes the track 166. The track 166 runs through theoperation cell 106. In this example, the vehicle 160 includes, or takesthe form of, the cart 164 that is configured to travel along the track166.

Referring to FIG. 20 , in an example, the manufacturing system 168includes the second operation cell 172. The manufacturing system 168also includes the second automated machine 174. The second automatedmachine 174 is located in the second operation cell 172 and configuredto perform at least one manufacturing operation on the workpiece 170.

The manufacturing system 168 also includes a second sensor 198. Thesecond sensor 198 is configured to detect (e.g., visually identify) theindexing feature 104. The controller 110 is in communication with thesecond sensor 198 and the second automated machine 174. The controller110 is configured to locate the fixture tool 102 relative to the secondoperation cell 172 from a second indexing-feature location 200 of theindexing feature 104, identified by the second sensor 198. Thecontroller 110 is also configured to index the second automated machine174 relative to a second fixture-tool location 180 of the fixture tool102. Once indexed, the second automated machine 174 performs at leastone manufacturing operation on the workpiece 170.

Referring generally to FIG. 1 and particularly to FIGS. 21-23 in anotherexample, the indexing apparatus 100 includes the fixture tool 102. Thefixture tool 102 is movable relative to the operation cell 106. Theindexing apparatus 100 also includes the indexing feature 104. Theindexing feature 104 is fixed relative to the fixture tool 102. Forexample, the indexing feature 104 is formed by, or is otherwise disposedon, the fixture tool 102.

In the examples illustrated in FIGS. 21-23 , the indexing feature 104 iscoupled to, or is located on, at least one side of the fixture tool 102.In other examples, the indexing feature 104 is coupled to, or is locatedon, another portion (e.g., an opposing side, a front, a rear, a top, abottom, etc.) of the fixture tool 102.

In an example, the indexing apparatus 100 includes the plurality ofprobes 202. The plurality of probes 202 is movable relative to theoperation cell 106 and the fixture tool 102. The plurality of probes 202is configured to engage (e.g., to make physical contact with) theindexing feature 104. The indexing feature 104 is appropriately locatedrelative to the fixture tool 102 so that at least a portion of theindexing feature 104 is physically accessible by the plurality of probes202. Conversely, the plurality of probes 202 is appropriately locatedrelative to the fixture tool 102 so that at least a portion of theplurality of probes 202 is physically accessible by the indexing feature104. With the plurality of probes 202 engaged to the indexing feature104, a plurality of locations of the plurality of probes 202 (alsoreferred to herein as a plurality of probe locations 204) (FIG. 1 ) isrepresentative of, or corresponds to, the indexing-feature location 116(FIG. 1 ). In other words, the plurality of probes 202 locates theindexing feature 104 in the reference frame 216.

Referring to FIGS. 21-23 , in an example of the indexing apparatus 100,the plurality of probes 202 form a portion of a probe assembly 250(e.g., the probe assembly 250 includes the plurality of probes 202). Theprobe assembly 250 includes a drive mechanism 252 that is coupled toeach one of the plurality of probes 202 associated with the probeassembly 250. The drive mechanism 252 is configured to move each one ofthe plurality of probes 202 (e.g., also referred to collectively asprobes 202 and individually as probe 202) relative to the fixture tool102 in at least one dimension of the fixed coordinate system 112. Forexample, the drive mechanism 252 is configured to linearly translate(e.g., extend and retract) each probe 202 in one dimension (e.g., aY-direction) of the fixed coordinate system 112.

The drive mechanism 252 includes at least one suitable drive motor (notshown) to drive motion of the probes 202, such as an electromechanicalmotor, a pneumatic motor, a hydraulic motor, and the like. The probeassembly 250 is also configured to provide location data (e.g., theinterface data 222) that represents a plurality of locations of theprobes 202, for example, relative to the reference frame 216 in at leastone dimension of the fixed coordinate system 112 (e.g., the plurality ofprobe locations 204). For example, the probe assembly 250 also includesat least one encoder (not shown) and/or at least one sensor (not shown)that converts motion of each probe 202 into an electrical signal thatrepresents the probe location 204 of the corresponding probe 202. Theprobe assembly 250 also includes other suitable electronic, mechanical,pneumatic, and hydraulic components (not shown). The drive mechanism 252operates under computer control, such as by the controller 110.

In the examples illustrated in FIGS. 21 and 22 , the indexing apparatus100 includes two probe assemblies 250, for example, that are oppositeeach other, so that the probes 202 associated with each one of the probeassemblies 250 engage corresponding indexing features 104, for example,disposed on opposing sides of the fixture tool 102. In another example,the indexing apparatus 100 includes one probe assembly 250 so that theprobes 202 associated with the probe assembly 250 engage the indexingfeature 104 disposed on the fixture tool 102.

Referring to FIGS. 1 and 21-23 , the indexing apparatus 100 alsoincludes the controller 110. The controller 110 is in communication withthe plurality of probes 202. The controller 110 is configured to locatethe fixture tool 102 relative to the operation cell 106 from theplurality of probe locations 204 of the plurality of probes 202, withthe plurality of probes 202 engaged to the indexing feature 104.

In an example of the indexing apparatus 100, the controller 110 isconfigured to determine the plurality of probe locations 204 of theplurality of probes 202, for example, relative to the reference frame216 in at least one dimension of the fixed coordinate system 112. Thecontroller 110 is also configured to determine the indexing-featurelocation 116 of the indexing feature 104, for example, relative to thereference frame 216 in the at least one dimension of the fixedcoordinate system 112, from the plurality of probe locations 204 of theplurality of probes 202. The controller 110 is further configured todetermine the fixture-tool location 118 of the fixture tool 102, forexample, relative to the reference frame 216 in the at least onedimension of the fixed coordinate system 112, from the indexing-featurelocation 116 of the indexing feature 104.

In an example, the controller 110 is configured to register the digitalmodel 120 (FIG. 1 ), representing the fixture tool 102 and the indexingfeature 104, to the indexing-feature location 116 of the indexingfeature 104. The controller 110 is also configured to convert the modellocation 126 of the digital model 120, registered to theindexing-feature location 116, to the fixture-tool location 118 of thefixture tool 102.

FIG. 24 schematically illustrates an example of the inputs 234 providedto the controller 110 and the outputs 236 generated by the controller110 during the locating and indexing operation. In an example,probe-location data 254 is provided to the controller 110 by the probeassembly 250. The probe-location data 254 is an example of the interfacedata 222 (FIG. 1 ). In an example, the probe-location data 254 isgenerated by encoders, sensors, other relative positioning devices, or acombination thereof and is representative of the actual, physicallocation of the plurality of probes 202 (the probe locations 204) (FIG.13 ). The controller 110 processes the probe-location data 254 anddetermines the probe locations 204 based on the probe-location data 254.The controller 110 then processes the probe locations 204 and determinesthe indexing-feature location 116 based on the probe locations 204.

Referring to FIGS. 21-23 , in an example, with the probes 202 engaged tothe indexing feature 104, there are a plurality of points of contactbetween the probes 202 and the indexing feature 104. Each one of thesepoints of contact has an XYZ-coordinate that is common to both thecorresponding probe 202 and the indexing feature 104. The probe-locationdata 254 (FIG. 24 ) represents an XYZ-coordinates of the points ofcontact of the probes 202 (e.g., the XYZ-coordinate of the point ofcontact of each probe 202) and the probe locations 204 are described bythe XYZ-coordinates of the points of contact of the probes 202. Thecontroller 110 converts the XYZ-coordinates of the points of contact ofthe probes 202 to XYZ-coordinates of corresponding points of contact ofthe indexing feature 104. The controller 110 then determines theindexing-feature location 116 as described by the XYZ-coordinates ofpoints of contact of the indexing feature 104.

In an example, the probe assembly 250 includes at least two probes 202corresponding to at least two points of contact between the probes 202and the indexing feature 104, which, in turn, provides at least twoXYZ-coordinates describing the indexing-feature location 116 of theindexing feature 104. In another example, the probe assembly 250includes at least three probes 202 corresponding to at least threepoints of contact between the probes 202 and the indexing feature 104,which, in turn, provides at least three XYZ-coordinates describing theindexing-feature location 116 of the indexing feature 104. In anotherexample, a combination of the probes 202 from two or more probeassemblies 250 correspond to at least three points of contact betweenthe probes 202 and the indexing feature 104, which, in turn, provides atleast three XYZ-coordinates describing the indexing-feature location 116of the indexing feature 104.

In an example, the plurality of points of contact are provided by theprobes 202 of one probe assembly 250 that engage the indexing feature104 disposed on the fixture tool 102. In another example, some of thepoints of contact are provided by the probes 202 associated in a firstprobe assembly 250 that engage a first portion of the indexing feature104 (or a first indexing feature 104) disposed on a first side (or firstsurface) of the fixture tool 102 and some of the points of contact areprovided by the probes 202 associated with a second probe assembly 250that engage a second portion of the indexing feature 104 (or a secondindexing feature 104) disposed on a second side (or second surface) ofthe fixture tool 102.

It should be noted that increasing the number of points of contactbetween the probes 202 and the indexing feature 104 (e.g., by increasingthe number of probes 202 engaged with the indexing feature 104) providesa greater number of XYZ-coordinate data points for processing, which, inturn, increases the accuracy of the indexing-feature location 116 andthe fixture-tool location 118 during data point alignment of theindexing operation.

In the illustrated examples, probes 202 (e.g., of opposing probeassemblies 250) are arranged to engage portions of the indexing feature104 (or different indexing features 104) that are disposed on theopposing sides (e.g., side surfaces) of the fixture tool 102. In otherexamples (not shown), probes 202 (e.g., from an additional or alternateprobe assembly 250) are arranged to engage portions of the indexingfeature 104 (or different indexing features 104) that are disposed onanother portion or another surface (e.g., a top, bottom, front, back,etc.) of the fixture tool 102.

Referring to FIG. 27 , in an example, the probe 202 includes thecontact-index 148 and the indexing feature 104 includes theinterface-index 146. With the probe 202 engaged to the indexing feature104, there is a point of contact between the contact-index 148 and theinterface-index 146. This point of contact has an XYZ-coordinate that iscommon to both the contact-index 148 and the interface-index 146. Theprobe-location data 254 represents an XYZ-coordinate of the point ofcontact of the contact-index 148 of the probe 202 and the probe location204 of the probe 202 is described by the XYZ-coordinate of the point ofcontact of the contact-index 148 of the probe 202.

The controller 110 converts the XYZ-coordinate of the point of contactof the contact-index 148 to an XYZ-coordinate of a corresponding pointof contact of the interface-index 146. The controller 110 determines theindexing-feature location 116 as described by the XYZ-coordinates ofpoints of contact of the interface-index 146.

Generally, the plurality of probes 202 includes, or forms, a pluralityof contact-indexes 148 and the indexing feature 104 includes, or forms,a plurality of interface-indexes 146, which, in turn, provides theplurality of points of contact. Accordingly, the probe-location data 254(FIG. 24 ) represents the XYZ-coordinates of the plurality of points ofcontact of the contact-indexes 148 of the plurality of probes 202. Theplurality of probe locations 204 is described by the XYZ-coordinates ofthe points of contact of the contact-indexes 148 of the plurality ofprobes 202. The indexing-feature location 116 is described by theXYZ-coordinates of the corresponding plurality of points of contact ofthe interface-indexes 146.

It should be noted that increasing the number of contact-indexes 148 andinterface-indexes 146 increases the number of points of contact betweenthe probes 202 and the indexing feature 104, which, in turn, provides agreater number of XYZ-coordinate data points for processing, which, inturn, increases the accuracy of the indexing-feature location 116 andthe fixture-tool location 118 during data point alignment of theindexing operation. In an example, the probe assembly 250 (e.g.,plurality of probes 202) includes at least three contact-indexes 148 andthe indexing feature 104 include at least three interface-indexes 146.

Referring again to FIG. 24 , the controller 110 is configured toregister the digital model 120, representing the fixture tool 102 andthe indexing feature 104, to the indexing-feature location 116 anddetermines the model location 126. In an example, the controller 110 isconfigured to overlay and align the digital model 120 with theXYZ-coordinates describing the indexing-feature location 116 within thereference frame 216. The digital model 120 includes data pointsrepresenting the points of contact of the indexing feature 104. Forexample, the digital model 120 includes data points that represent theinterface-index 146 of the indexing feature 104. In an example, thecontroller 110 performs a best fit operation (e.g., executed a best fitalgorithm) to align data points representing the points of contact ofthe indexing feature 104, such as the data points representing theinterface-indexes 146, with data points representing the XYZ-coordinatesdescribing the indexing-feature location 116. In an example, the bestfit operation includes a rigid body, point cloud transformationoperation.

With the digital model 120 registered and aligned with theindexing-feature location 116, the controller 110 is configured toconvert the model location 126 to the fixture-tool location 118 of thefixture tool 102 relative to the reference frame 216. For example, thefixture-tool location 118 is assumed to be the same as the modellocation 126 within tolerance. Thus, the fixture-tool location 118represents the immediate (e.g., current, real-time) location of thefixture tool 102 and, thus, the workpiece 170 relative to the operationcell 106 and the automated machine 128.

With the fixture-tool location 118 known, the automated machine 128 isindexed, or is “zeroed”, relative to the fixture-tool location 118 andfollows the predetermined tool path to perform the manufacturingoperation on the workpiece 170. Indexing the automated machine 128relative to the fixture tool 102, based on the fixture-tool location118, consequently indexes the automated machine 128 relative to theworkpiece 170. The geometry of the workpiece 170 and the known locationof the workpiece 170 relative to the fixture tool 102 are incorporatedin and are accounted for by the programmed tool path of the automatedmachine 128.

Referring to FIGS. 1 and 21 , in an example, the indexing apparatus 100includes the automated machine 128. The automated machine 128 is locatedin the operation cell 106. The automated machine 128 is in communicationwith the controller 110. The controller 110 is configured to index theautomated machine 128 relative to the fixture-tool location 118 of thefixture tool 102.

Referring to FIGS. 22 and 23 , in an example, the automated machine 128includes the gantry 134. In this example, the fixture tool 102 and,thus, the workpiece 170 is moved to the work location 258 within theoperation cell 106 and the gantry 134 and/or the robotic arm 226,coupled to the gantry 134, moves relative to the fixture tool 102 sothat the end effector 228 follows along the predetermined tool path.

In another example (not shown), the robotic arm 226 is a stand-alonerobot that has a fixed base within the operation cell 106. In thisexample, the fixture tool 102 and, thus, the workpiece 170 is moved tothe work location 258 within the operation cell 106 and the robotic arm226 moves relative to the fixture tool 102 so that the end effector 228follows along the predetermined tool path.

While the illustrated examples of the indexing apparatus 100 show onlyone automated machine 128 (e.g., one robotic arm 226 with one endeffector 228) for performing the manufacturing operation on theworkpiece 170 in the operation cell 106, in other examples, the indexingapparatus 100 may have any number of additional automated machines 128(e.g., additional robotic arms 226 and/or additional end effectors 228).

Referring to FIGS. 1 and 22 , in an example, the manufacturing operationincludes a pre-cure composite assembly operation, such as the compositelayup operation and/or composite lamination operation. In this example,the workpiece 170 includes a composite laminate (e.g., layup of acomposite material). The fixture tool 102 includes, or takes the formof, the mandrel 130. The mandrel 130 is configured to support thecomposite laminate. The automated machine 128 includes, or takes theform of, the automated fiber placement machine 132.

In an example, the fixture tool 102 is moved into the work location 258and the immediate location of the fixture tool 102 and the workpiece 170(e.g., the fixture-tool location 118) is determined using the pluralityof probes 202 and the indexing feature 104, as described above. Based onthe fixture-tool location 118 (e.g., the location of the fixture tool102 and the location of the workpiece 170 relative to the fixture tool102), the automated fiber placement machine 132 lays down and/orconsolidates at least a portion of at least one layer of a stack ofcomposite sheets.

In one or more other examples (not explicitly illustrated), themanufacturing operation includes another assembly operation or machiningoperation. In such examples, the workpiece 170 may be a post-curecomposite workpiece, metallic workpiece, plastic workpiece, or othernon-composite workpiece. The fixture tool 102 includes the suitableholding-features 260 (FIG. 1 ) configured to secure the workpiece 170during movement to the operation cell 106 and during the manufacturingoperation. The automated machine 128 includes, or takes the form of, anyappropriate machine tool.

In an example, the indexing apparatus 100 includes the independentmoving mechanism (not shown) that is configured to move the fixture tool102 to the work location 258.

FIGS. 25 and 26 schematically illustrate examples of the indexingfeature 104. FIG. 27 schematically illustrates an example of the probe202 and the indexing feature 104. Generally, the indexing feature 104includes at least one interface-index 146. In an example, theinterface-index 146 is disposed on (e.g., located or formed on) thesurface 194 of the fixture tool 102. Each one of the plurality of probes202 includes the contact-index 148 (FIG. 27 ). The contact-index 148 ismovable relative to the at least one interface-index 146. Thecontact-index 148 is configured to engage the interface-index 146 toenable the probe 202 to locate the indexing feature 104.

Referring to FIG. 27 , in an example, each probe 202 includes a probehead 208. The probe 202 is configured to move in at least one dimensionof the fixed coordinate system 112 relative to the fixture tool 102 toengage the probe head 208 with the indexing feature 104. In an example,each probe 202 includes a probe shaft 256. The probe head 208 is coupledto an end of the probe shaft 256. The drive mechanism 252 is configuredto extend and retract the probe shaft 256 to move the probe head 208.

In an example, the interface-index 146 includes, or is formed by, atleast one interfacing-structure 206 that is located on the surface 194of the fixture tool 102. For example, the interface-index 146 is formedby a portion of interfacing-structure 206, such as a portion of asurface of the interfacing-structure 206. In an example, thecontact-index 148 includes, or is formed by, the probe head 208. In thisexample, the probe head 208 is the contacting-structure of thecontact-index 148. For example, contact-index 148 is formed by a portionof the probe head 208, such as a portion of a surface of the probe head208.

In an example, the probe head 208 is configured to engage theinterfacing-structure 206 so that the contact-index 148 contacts theinterface-index 146. The contact-index 148 and the interface-index 146are configured to contact and mate with each other when the probe 202(e.g., the probe head 208) properly engages the indexing feature 104(e.g., the interfacing-structure 206).

Referring to FIG. 25 , in an example of the indexing feature 104, theinterfacing-structure 206 is continuous and extends longitudinally alongthe surface 194 (e.g., a side surface) of the fixture tool 102. In otherwords, the interfacing-structure 206 may be a continuousinterfacing-structure. In an example, the interfacing-structure 206 maybe linear, as illustrated in FIG. 25 . In another example, theinterfacing-structure 206 may be non-linear.

Referring to FIG. 26 , in another example of the indexing feature 104,the interfacing-structure 206 is discontinuous and extendslongitudinally along the surface 194 of the fixture tool 102. In otherwords, the interfacing-structure 206 may be a plurality of discontinuousinterface point structures (e.g., also referred to herein as a pluralityof interfacing-structures 206). In an example, the plurality ofinterfacing-structures 206 may be arranged linearly. In another example,the plurality of interfacing-structures 206 may be arrangednon-linearly, as illustrated in FIG. 26 .

In an example, the probe head 208 and the interfacing-structure 206 havecomplementary geometric shapes and dimensions so that correspondingsurfaces of the probe head 208 (e.g., forming the contact-index 148) andinterfacing-structure 206 (e.g., forming the interface-index 146) are incontact when the probe 202 properly engages the indexing feature 104.Each one of the probe head 208 and the interfacing-structure 206includes, or takes the form of, any one of various structuralconfigurations.

In an example, the interfacing-structure 206 is a continuous grooveformed in (e.g., depending from) the surface 194 of the fixture tool102. In this example, the probe head 208 is configured to be inserted ina portion of the interfacing-structure 206. In another example, theinterfacing-structure 206 is a continuous ridge formed on (e.g.,projecting from) the surface 194 of the fixture tool 102. In thisexample, the probe head 208 is configured to receive a portion of theinterfacing-structure 206. In another example, each one of the pluralityof interfacing-structures 206 includes an aperture formed in (e.g.,depending from) the surface 194. In this example, the probe head 208 isconfigured to be inserted in the interfacing-structure 206. In anotherexample, each one of the plurality of interfacing-structures 206includes a protrusion formed on (e.g., projecting from) the surface 194.In this example, the probe head 208 is configured to receive theinterfacing-structure 206.

Other structural configurations and/or arrangements of the contact-index148 (e.g., the probe head 208) and the interface-index 146 (e.g., theinterfacing-structure 206) are also contemplated.

In another example of the indexing feature 104, theinterfacing-structure 206 includes, or takes the form of, at least onesurface 194 (e.g., an exterior surface) of the fixture tool 102. Inother words, the surface 194 of the fixture tool 102 is theinterfacing-structure 206 of the interface-index 146. Each one of theplurality of probes 202 is configured to move the probe head 208 intocontact with the surface 194 of the fixture tool 102. For example, thedrive mechanism 252 extends the probe shaft 256 to move the probe head208 into contact with the surface 194 and, thus, place the contact-index148, formed by a portion of the surface of the probe head 208, incontact with the interface-index 146, formed by a portion of the surface194 of the fixture tool 102.

Referring to FIG. 27 , in an example of the indexing apparatus 100, theprobe assembly 250 includes a displacement sensor 210. The displacementsensor 210 is in communication with each one of the plurality of probes202. The displacement sensor 210 is configured to measure a displacementof the plurality of probes 202 (e.g., each one of the probes 202) in theat least one dimension of the fixed coordinate system 112, when theplurality of probes 202 moves into contact with the indexing feature104. In an example, the displacement sensor 210 generates displacementdata representing the displacement or movement of the probe 202 andcorresponding to the probe location 204. This displacement data is anexample of the probe-location data 254 (FIG. 24 ) provided to thecontroller 110.

Referring to FIGS. 21-23 , in an example, the indexing apparatus 100includes the vehicle 160. The vehicle 160 is configured to support thefixture tool 102 and to move the fixture tool 102 relative to theoperation cell 106. In an example, the vehicle 160 is configured to movethe fixture tool 102 and, thus, the workpiece 170 to the work location258 at which the plurality of probes 202 extend into engagement with theindexing feature 104 to perform the locating and indexing operationsdescribed above.

Referring to FIG. 1 , in an example of the indexing apparatus 100, thevehicle 160 includes, or takes the form of, the automated guided vehicle162. Referring to FIGS. 1 and 22 , in an example of the indexingapparatus 100, the vehicle 160 includes, or takes the form of, the cart164. The cart 164 is configured to travel along the track 166 runningthrough the operation cell 106.

In an example, the track 166 is arranged such that the Z-coordinate ofthe fixture tool 102 and, thus, the indexing feature 104 is fixed andremains constant as the cart 164 travels along the track 166 to the worklocation 258. In this example, the locating operation performed by theplurality of probes 202 need only to determine the XY-coordinate of theindexing feature 104.

Referring to FIGS. 1 and 21 , in another example, the manufacturingsystem 168 includes the operation cell 106 and the automated machine128. The automated machine 128 is located in the operation cell 106 andis configured to perform at least one manufacturing operation. Themanufacturing system 168 also includes the fixture tool 102. The fixturetool 102 is configured to support the workpiece 170 and is movablerelative to the operation cell 106. The manufacturing system 168 furtherincludes the indexing feature 104. The indexing feature 104 is fixedrelative to the fixture tool 102. For example, the indexing feature 104is located on the fixture tool 102.

The manufacturing system 168 also includes the plurality of probes 202.The plurality of probes 202 is movable relative to the operation cell106 and the fixture tool 102. The plurality of probes 202 is configuredto engage the indexing feature 104. The manufacturing system 168 furtherincludes the controller 110 that is in communication with the pluralityof probes 202 and the automated machine 128. The controller 110 isconfigured to locate the fixture tool 102 relative to the operation cell106 from the plurality of probe locations 204 of the plurality of probes202, engaged with the indexing feature 104. The controller 110 is alsoconfigured to index the automated machine 128 relative to thefixture-tool location 118 of the fixture tool 102.

Referring to FIGS. 1 and 24 , in an example of the manufacturing system168, the controller 110 is configured to determine the plurality ofprobe locations 204 of the plurality of probes 202, for example,relative to the reference frame 216 in at least one dimension of thefixed coordinate system 112. The controller 110 is also configured todetermine the indexing-feature location 116 of the indexing feature 104,for example, relative to the reference frame 216 in the at least onedimension of the fixed coordinate system 112, from the plurality ofprobe locations 204 of the plurality of probes 202. The controller 110is further configured to determine the fixture-tool location 118 of thefixture tool 102, for example, relative to the reference frame 216 inthe at least one dimension of the fixed coordinate system 112, from theindexing-feature location 116 of the indexing feature 104. Thecontroller 110 is also configured to register the digital model 120,representing the fixture tool 102 and the indexing feature 104, to theindexing-feature location 116 of the indexing feature 104 and to convertthe model location 126 of the digital model 120, registered to theindexing-feature location 116, to the fixture-tool location 118 of thefixture tool 102.

Referring to FIGS. 1 and 21 , in an example of the manufacturing system168, the fixture tool 102 includes, or takes the form of, the mandrel130 that is configured to support a composite laminate and the automatedmachine 128 includes, or takes the form of, an automated fiber placementmachine 132.

Referring to FIGS. 21 and 22 , in an example of the manufacturing system168, the plurality of probes 202 is configured engage the indexingfeature 104 while the fixture tool 102 is inside of the work envelope140 of the operation cell 106. In an example of the manufacturing system168, the indexing feature 104 includes, or takes the form of, at leastone surface 194 of the fixture tool 102. Each one of the plurality ofprobes 202 moves into contact with the at least one surface 194 along atleast one dimension of the fixed coordinate system 112.

Referring to FIGS. 23 and 25-27 , in an example of the manufacturingsystem 168, the indexing feature 104 includes at least oneinterface-index 146 that is located on the surface 194 of the fixturetool 102. Each one of the plurality of probes 202 includes thecontact-index 148 that is movable relative to the at least oneinterface-index 146 and that is configured to engage the at least oneinterface-index 146. In an example, the interface-index 146 includes theinterfacing-structure 206 and the contact-index 148 includes the probehead 208 of a corresponding one of the plurality of probes 202. Theprobe head 208 is configured to engage the interfacing-structure 206 sothat the contact-index 148 contacts the interface-index 146.

Referring to FIGS. 1 and 21-23 , in an example, the manufacturing system168 includes vehicle 160. The vehicle 160 is configured to support thefixture tool 102 and to move the fixture tool 102 relative to theoperation cell 106.

Referring to FIGS. 1 and 21 , in an example, the manufacturing system168 also includes the track 166. The track 166 runs through theoperation cell 106. In this example, the vehicle 160 includes, or takesthe form of, the cart 164 that is configured to travel along the track166.

Referring to FIG. 28 , in an example, the manufacturing system 168includes the second operation cell 172 and the second automated machine174. The second automated machine 174 is located in the operation cell106 and is configured to perform at least one manufacturing operation.

The manufacturing system 168 also includes a second plurality of probes212. The second plurality of probes 212 is movable relative to thesecond operation cell 172 and the fixture tool 102. The second pluralityof probes 212 is configured to engage the indexing feature 104. Thecontroller 110 is in communication with the second plurality of probes212 and the second automated machine 174. The controller 110 isconfigured to locate the fixture tool 102 relative to the secondoperation cell 172 from a second plurality of probe locations 214 of thesecond plurality of probes 212, engaged with the indexing feature 104.The controller 110 is further configured to index the second automatedmachine 174 relative to a second fixture-tool location 180 of thefixture tool 102. Once indexed, the second automated machine 174performs at least one manufacturing operation on the workpiece 170.

Referring to FIGS. 10, 20 and 28 , in an example of the manufacturingsystem 168, the track 166 extends from the operation cell 106 to thesecond operation cell 172 and runs through the second operation cell172. In other words, the track 166 links the operation cell 106 to thesecond operation cell 172 together. As illustrated in FIGS. 10, 20 and28 , in an example, the operation cell 106 and the second operation cell172 are arranged in a continuous linked sequence. In these examples, themanufacturing system 168 is a continuous flow manufacturing system inwhich at least a portion of one or more manufacturing operations isperformed in each operation cell. While only two operation cells (e.g.,the operation cell 106 and the second operation cell 172) are shown byexample in FIGS. 10, 20 and 28 , in other examples, the manufacturingsystem 168 may include any number of operation cells.

In the examples illustrated in FIGS. 10, 20 and 28 , an entirety of thefixture tool 102 and an entirely of the workpiece 170 are located in acorresponding one of the operation cell 106 and the second operationcell 172, as the fixture tool 102 and the workpiece 170 travelcontinuously along the manufacturing system 168. However, in anotherexample, the fixture tool 102 and the workpiece 170 extend between morethan one operation cell of the manufacturing system 168. For example, afirst portion (or first section) of the fixture tool 102 and a firstportion (or first section) of the workpiece 170 are located in theoperation cell 106 and a second portion (or second section) of thefixture tool 102 and a second portion (or second section) of theworkpiece 170 are located in the second operation cell 172. In thisexample of the manufacturing system 168, the operation cell 106 and thesecond operation cell 172 depend upon each other such that themanufacturing operation performed in the second operation cell 172builds upon or adds to the manufacturing operation performed in theoperation cell 106. This arrangement is particularly advantageous forexamples in which the fixture tool 102 and the workpiece 170 are large,elongate structures. For example, the workpiece 170 may be a spar, awing section, or a fuselage section of an aircraft and the fixture tool102 is a fixture that is configured to support and securely hold thelarge workpiece 170.

In other examples (not shown) of the manufacturing system 168, theoperation cell 106 and the second operation cell 172 are separatelylocated and independent of each other. In this example, the vehicle 160(e.g., the automated guided vehicle 162) is configured to move along thepredefined travel path to move the fixture tool 102 and the workpiece170 between the different operation cells.

In the examples illustrated herein, the fixture tool 102 is a rigid bodyand the indexing feature 104 is coupled to the fixture tool 102.However, in other examples, the fixture tool 102 and the vehicle 160form a rigid body. For example, the fixture tool 102 and the vehicle 160may be integrated into a unitary member. In such examples, the locationof the indexing feature 104 is also fixed relative to the vehicle 160.For example, the indexing feature 104 may be coupled to, disposed on, orotherwise associated with the vehicle 160, rather than the fixture tool102.

As described herein, the locating and indexing operations advantageouslyenable the fixture tool 102 and the workpiece 170 to be moved into anapproximate location within the operation cell 106 relative to theautomated machine 128. The immediate location of the fixture tool 102(e.g., the fixture-tool location 118), for example, as determined by thegripper 108, the sensor 184, or the probes 202 described above, becomesthe work location 258 and the automated machine 128 indexes itself fromthe fixture-tool location 118. This operation improves the cycle time ofthe manufacturing operation by eliminating the need for incrementalindexing of the automated machine 128 relative to the workpiece 170 andthe need for setting up the workpiece 170 in a specific, predeterminedlocation using a non-movable fixture.

As described herein, the locating and indexing operations alsoadvantageously enable subsequent fixture tools 102 and workpieces 170 tobe located at moderately different working locations within theoperation cell 106 and relative to the automated machine 128. In otherwords, the work location 258 of the fixture tool 102 and the workpiece170, at which the manufacturing operation is performed, does not need tobe same, fixed and repeatable, location for subsequent workpieces 170.

While not explicitly illustrated, in one or more examples of theindexing apparatus 100 and/or manufacturing system 168, the interfacingdevice 220 includes a combination (e.g., two or more) of the gripper108, the sensor 184, and/or the probes 202. The combination of thegripper 108, the sensor 184, and/or the probes 202 is used to interfacewith corresponding indexing features 104 to locate and index the fixturetool 102 based on the location of the indexing feature 104.

FIG. 29 is a flow diagram of an example of the method 1000 ofmanufacturing. Referring generally to FIGS. 1-10 and particularly toFIG. 29 , the method 1000 includes a step of (block 1002) securing theworkpiece 170 to the fixture tool 102. With the workpiece 170 secured tothe fixture tool 102, the location of the workpiece 170 (the workpiecelocation 262) is fixed and is known relative to the fixture tool 102.Additionally, the geometry of the workpiece 170 (the workpiece geometry268) is known. In accordance with the method 1000, locating the fixturetool 102 relative to the operation cell 106 (e.g., relative to thereference frame 216), in turn, locates the workpiece 170 relative to theoperation cell 106 (e.g., relative to the reference frame 216).

The method 1000 includes a step of (block 1004) moving the fixture tool102 relative to the operation cell 106. The method 1000 also includes astep of (block 1006) engaging the indexing feature 104 with the gripper108. The location of the indexing feature 104 (the indexing-featurelocation 116) is fixed and is known relative to the fixture tool 102. Inan example, the indexing feature 104 is coupled to the fixture tool 102.The method 1000 further includes a step of (block 1010), with thegripper 108 engaged to the indexing feature 104, locating the fixturetool 102 relative to the operation cell 106 from the location of thegripper 108 (the gripper location 114).

The method 1000 includes a step of (block 1016) indexing the automatedmachine 128 relative to the location of the fixture tool 102 (thefixture-tool location 118). In accordance with the method 1000, indexingthe automated machine 128 relative to the location of the fixture tool102 (the fixture-tool location 118), in turn, indexes the automatedmachine 128 relative to the location of the workpiece 170 (the workpiecelocation 262). The method 1000 further includes a step of (block 1018)performing at least one manufacturing operation on the workpiece 170,using the automated machine 128. With the automated machine 128 indexedrelative to the location of the fixture tool 102 (the fixture-toollocation 118), the geometry of the workpiece 170 (the workpiece geometry268) and the location of the workpiece 170 (the workpiece location 262)relative to the fixture tool 102 are incorporated in and are accountedfor by the programmed tool path of the automated machine 128 duringperformance of the manufacturing operation.

In an example, the method 1000 includes a step of (block 1008)determining the location of the gripper 108 (the gripper location 114)relative to the operation cell 106, for example, relative to thereference frame 216 in at least one dimension of the fixed coordinatesystem 112. The method 1000 also includes a step of (block 1012)determining the location of the indexing feature 104 (theindexing-feature location 116) relative to the operation cell 106, forexample, relative to the reference frame 216 in the at least onedimension of the fixed coordinate system 112, from the location of thegripper 108 (the gripper location 114). The method 1000 further includesa step of (block 1014) determining the location of the fixture tool 102(the fixture-tool location 118) relative to the operation cell 106, forexample, relative to the reference frame 216 in the at least onedimension of the fixed coordinate system 112, from the location of theindexing feature 104 (the indexing-feature location 116).

In an example, the method 1000 includes a step of registering thedigital model 120, representing the fixture tool 102 and the indexingfeature 104, to the location of the indexing feature 104 (theindexing-feature location 116). The method 1000 also includes a step ofconverting the location of the digital model 120 (the model location126), registered to the location of the indexing feature 104 (theindexing-feature location 116), to the location of the fixture tool 102(the fixture-tool location 118). In other words, the location of thefixture tool 102 (the fixture-tool location 118) is assumed (withintolerance) to be the same as the location of the digital model 120 (themodel location 126) when the digital model 120 is registered to thelocation of the indexing feature 104 (the indexing-feature location116).

In an example, the method 1000 includes a step of moving the fixturetool 102 to the work location 258 (e.g., within the work envelope 140 ofthe operation cell 106) using the gripper 108, while (e.g.,approximately concurrent with) performing the steps of (block 1008)determining the location of the gripper 108 (the gripper location 114)and (block 1008) determining the location of the indexing feature 104(the indexing-feature location 116).

In an example, the method 1000 includes a step of engaging theinterface-index 146 of the indexing feature 104 with the contact-index148 of the gripper 108, for example, when performing the step of (block1004) engaging the indexing feature 104 with the gripper 108. The method1000 also includes a step of generating the gripper-location data 238,representing XYZ-coordinates of the points of contact between thecontact-index 148 and the interface-index 146.

In an example, the method 1000 includes a step of gripping the plate 150of the indexing feature 104 with the jaw assembly 144 of the gripper108. The method 1000 also includes a step of engaging theinterface-index 146, coupled to the plate 150, with the contact-index148, coupled to the jaw assembly 144.

FIG. 30 is a flow diagram of an example of the method 2000 ofmanufacturing. Referring generally to FIGS. 1 and 11-20 and particularlyto FIG. 30 , in an example, the method 3000 includes a step of (block2002) securing the workpiece 170 to the fixture tool 102. With theworkpiece 170 secured to the fixture tool 102, the location of theworkpiece 170 (the workpiece location 262) is fixed and is knownrelative to the fixture tool 102. Additionally, the geometry of theworkpiece 170 (the workpiece geometry 268) is known. In accordance withthe method 1000, locating the fixture tool 102 relative to the operationcell 106 (e.g., relative to the reference frame 216), in turn, locatesthe workpiece 170 relative to the operation cell 106 (e.g., relative tothe reference frame 216).

The method 2000 includes a step of (block 2004) moving the fixture tool102 relative to the operation cell 106. The method 2000 also includes astep of (block 2006) detecting (e.g., visually identifying) the indexingfeature 104 with the sensor 184. The location of the indexing feature104 (the indexing-feature location 116) is fixed and is known relativeto the fixture tool 102. In an example, the indexing feature 104 islocated on the fixture tool 102. The method 2000 further includes a stepof (block 2008) locating the fixture tool 102 relative to the operationcell 106 from the location of the indexing feature 104 (theindexing-feature location 116), detected by the sensor 184.

The method 2000 also includes a step of (block 2014) indexing theautomated machine 128 relative to the location of the fixture tool 102(the fixture-tool location 118). In accordance with the method 2000,indexing the automated machine 128 relative to the location of thefixture tool 102 (the fixture-tool location 118), in turn, indexes theautomated machine 128 relative to the location of the workpiece 170 (theworkpiece location 262). The method 2000 further includes a step of(block 2016) performing at least one manufacturing operation on theworkpiece 170, using the automated machine 128. With the automatedmachine 128 indexed relative to the location of the fixture tool 102(the fixture-tool location 118), the geometry of the workpiece 170 (theworkpiece geometry 268) and the location of the workpiece 170 (theworkpiece location 262) relative to the fixture tool 102 areincorporated in and are accounted for by the programmed tool path of theautomated machine 128 during performance of the manufacturing operation.

In an example, the method 2000 includes a step of (block 2010)determining the location of the indexing feature 104 (theindexing-feature location 116) relative to the operation cell 106, forexample, relative to the reference frame 216 in at least one dimensionof the fixed coordinate system 112, from the sensor data 186, generatedby the sensor 184. The method 2000 also includes a step of (block 2012)determining the location of the fixture tool 102 (the fixture-toollocation 118) relative to the operation cell 106, for example, relativeto the reference frame 216 in the at least one dimension of the fixedcoordinate system 112, from the location of the indexing feature 104(the indexing-feature location 116).

In an example, the method 2000 includes a step of registering thedigital model 120, representing the fixture tool 102 and the indexingfeature 104, to the location of the indexing feature 104 (theindexing-feature location 116). The method 2000 also includes a step ofconverting the location of the digital model 120 (the model location126), registered to the location of the indexing feature 104 (theindexing-feature location 116), to the location of the fixture tool 102(the fixture-tool location 118). In other words, the location of thefixture tool 102 (the fixture-tool location 118) is assumed (withintolerance) to be the same as the location of the digital model 120 (themodel location 126) when the digital model 120 is registered to thelocation of the indexing feature 104 (the indexing-feature location116).

In an example, the method 2000 includes a step of detecting (e.g.,visually detecting) at least one interfacing-structure 192 of theindexing feature 104, located on the surface 194 of the fixture tool102, using the sensor 184. The method 2000 also includes a step ofgenerating the sensor data 186, representing XYZ-coordinates of theinterfacing-structure 192.

FIG. 31 is a flow diagram of an example of the method 3000 ofmanufacturing. Referring generally to FIGS. 1 and 21-28 and particularlyto FIG. 30 , the method 3000 includes a step of (block 3002) securingthe workpiece 170 to the fixture tool 102. With the workpiece 170secured to the fixture tool 102, the location of the workpiece 170 (theworkpiece location 262) is fixed and is known relative to the fixturetool 102. Additionally, the geometry of the workpiece 170 (the workpiecegeometry 268) is known. In accordance with the method 1000, locating thefixture tool 102 relative to the operation cell 106 (e.g., relative tothe reference frame 216), in turn, locates the workpiece 170 relative tothe operation cell 106 (e.g., relative to the reference frame 216).

The method 3000 includes a step of (block 3004) moving the fixture tool102 relative to the operation cell 106. The method 3000 also includes astep of (block 3006) engaging the indexing feature 104 with theplurality of probes 202. The location of the indexing feature 104 (theindexing-feature location 116) is fixed and is known relative to thefixture tool 102. In an example, the indexing feature 104 is coupled tothe fixture tool 102. The method 3000 further includes a step of (block3010), with the plurality of probes 202 engaged to the indexing feature104, locating the fixture tool 102 relative to the operation cell 106from the locations of the plurality of probes 202 (the plurality ofprobe locations 204).

The method 3000 further includes a step of (block 3016) indexing theautomated machine 128 relative to the location of the fixture tool 102(the fixture-tool location 118). In accordance with the method 3000,indexing the automated machine 128 relative to the location of thefixture tool 102 (the fixture-tool location 118), in turn, indexes theautomated machine 128 relative to the location of the workpiece 170 (theworkpiece location 262). The method 3000 further includes a step of(block 3018) performing at least one manufacturing operation on theworkpiece 170, using the automated machine 128. With the automatedmachine 128 indexed relative to the location of the fixture tool 102(the fixture-tool location 118), the geometry of the workpiece 170 (theworkpiece geometry 268) and the location of the workpiece 170 (theworkpiece location 262) relative to the fixture tool 102 areincorporated in and are accounted for by the programmed tool path of theautomated machine 128 during performance of the manufacturing operation.

In an example, the method 3000 includes a step of (block 3008)determining the locations of the plurality of probes 202 (the pluralityof probe locations 204) relative to the operation cell 106, for example,relative to the reference frame 216 in at least one dimension of thefixed coordinate system 112. The method 3000 also includes at step of(block 3012) determining the location of the indexing feature 104 (theindexing-feature location 116) relative to the operation cell 106, forexample, relative to the reference frame 216 in the at least onedimension of the fixed coordinate system 112, from the locations of theplurality of probes 202 (the plurality of probe locations 204). Themethod 3000 further includes a step of (block 3014) determining thelocation of the fixture tool 102 (the fixture-tool location 118)relative to the operation cell 106, for example, relative to thereference frame 216 in the at least one dimension of the fixedcoordinate system 112, from the location of the indexing feature 104(the indexing-feature location 116).

In an example, the method 3000 includes a step of registering thedigital model 120, representing the fixture tool 102 and the indexingfeature 104, to the location of the indexing feature 104 (theindexing-feature location 116). The method 3000 includes a step ofconverting the location of the digital model 120 (the model location126), registered to the location of the indexing feature 104 (theindexing-feature location 116), to the location of the fixture tool 102(the fixture-tool location 118). In other words, the location of thefixture tool 102 (the fixture-tool location 118) is assumed (withintolerance) to be the same as the location of the digital model 120 (themodel location 126) when the digital model 120 is registered to thelocation of the indexing feature 104 (the indexing-feature location116).

In an example, the method 3000 includes a step of moving the fixturetool 102 to the work location 258 (e.g., within the work envelope 140 ofthe operation cell 106). The method 3000 also includes a step of movingthe plurality of probes 202 into contact with the indexing feature 104along at least one dimension of the fixed coordinate system 112.

In an example, the method 3000 includes a step of engaging theinterface-index 146 of the indexing feature 104 with the contact-index148 of each one of the probes 202, for example, when performing the stepof (block 3006) engaging the indexing feature 104 with the plurality ofprobes 202. The method 3000 also includes a step of generating theprobe-location data 254, representing XYZ-coordinates of the points ofcontact between the contact-index 148 and the interface-index 146.

In an example, the method 3000 includes a step of engaging theinterfacing-structure 206 of the indexing feature 104 with the probehead 208 of the probe 202. The method 1000 also includes a step ofengaging the interface-index 146, formed by the interfacing-structure206, with the contact-index 148, formed by the probe head 208.

FIG. 32 schematically illustrates an example of the controller 110 and,more particularly, a computing device 224 of the controller 110. Thecontroller 110 includes any suitable programmable controller that isconfigured to control of one or more manufacturing processes and toexecute one or more computing or data processing operations. Theoperations performed by the various examples of the disclosed indexingapparatus 100, the manufacturing system 168 and the methods 1000, 2000,3000 and/or portions thereof are implemented under computer controlprovided by the controller 110. The controller 110 may be any number ofprogrammable controllers and/or include any number of computing devices224.

The computing device 224 is an example of a data processing system usedto perform one or more of the functions provided by the disclosedindexing apparatus 100 and manufacturing system 168 or to implement oneor more of the operational steps of the disclosed methods 1000, 2000,3000. The computing device 224 includes a communications bus 602, whichprovides communications between a processor unit 604, memory 606,persistent storage 608, a communications unit 610, an input/output(“I/O”) unit 612, and a display 614.

The communications bus 602 includes one or more buses, such as a systembus or an input/output bus. The communications bus 602 is implementedusing any suitable type of architecture that provides for a transfer ofdata between different components or devices attached to the bus system.

The processor unit 604 is any suitably programmed computer processorconfigured to execute instructions, such as software instructions loadedonto the memory 606. The processor unit 604 may be any number ofprocessors, a multi-processor core, a microprocessor, or any other typeof processor, depending upon implementation of the controller 110.

The memory 606 and the persistent storage 608 are examples of storagedevices 616. The storage device 616 is any piece of hardware that iscapable of storing information including, but not limited to, data,program code in functional form, and/or other suitable informationeither on a temporary basis and/or a permanent basis. For example, thememory 606 may be a random-access memory or any other suitable volatileor non-volatile storage device. The memory 606 may also be referred toas a non-transitory computer-readable storage medium.

The persistent storage 608 may take various forms, depending onimplementation. The persistent storage 608 may contain one or morecomponents or devices. For example, persistent storage 608 may be a harddrive, a flash memory, a rewritable optical disk, a rewritable magnetictape, or some combination thereof.

The communications unit 610 provides for communication with other dataprocessing systems or devices, such as by a wired and/or wirelesscommunications links. The communications unit 610 may include one ormore devices used to transmit and receive data, such as a networkinterface card, a modem, or a network adapter.

The input/output unit 612 enables input and output of data with otherdevices connected to controller 110. For example, the input/output unit612 may provide a connection for input through a keyboard, a mouse,and/or some other suitable input device. Further, the input/output unit612 may send output to the display 614 for display of information.

Instructions for the operating system, applications, and/or programs maybe located in the storage devices 616, which are in communication withthe processor unit 604 through the communications bus 602. In anexample, computer-implemented instructions are in a functional form onthe persistent storage 608. The instructions are loaded into the memory606 for execution by processor unit 604. One or more of the processesand/or operations described herein are performed by the processor unit604 using the computer implemented instructions.

The computer-implemented instructions may be referred to as programcode, computer usable program code, or computer readable program codethat is readable and executable by at least one processor of theprocessor unit 604. The program code may be embodied on differentphysical or computer readable storage media, such as the memory 606 orthe persistent storage 608.

In an example, program code 618 is in a functional form on computerreadable media 620, which is selectively removable and may be loadedonto or transferred to the computing device 224 for execution by theprocessor unit 604. In an example, the program code 618 and the computerreadable media 620 form a computer program product 622. The computerreadable media 620 may be computer readable storage media 624 orcomputer readable signal media 626.

Computer readable storage media 624 may include, but is not limited to,an optical or magnetic disk that is inserted or placed into a drive orother device that is part of persistent storage 608 for transfer onto astorage device, such as a hard drive, that is part of persistent storage608. The computer readable storage media 624 may take the form of apersistent storage, such as a hard drive, a thumb drive, a networkapparatus, the cloud, flash memory, optical disk, magnetic disk, and thelike. The computer readable storage media 624 is connected or isotherwise transferred to the computing device 224.

In an example, the operations performed by the various examples of thedisclosed indexing apparatus 100 and manufacturing system 168 and theoperational steps implemented by the various examples of the disclosedmethods 1000, 2000, 3000 and/or portions thereof may be implemented asor utilize a computer program product that includes a non-transitorycomputer readable memory medium and computer controlling instructionsstored on the non-transitory computer readable memory medium that isexecuted by a computer processor.

Thus, various implementations of the apparatuses, systems, and methodsdescribed herein may be realized in digital electronic circuitry,integrated circuitry, specially designed ASICs (application specificintegrated circuits), computer hardware, firmware, software, and/orcombinations thereof. The various implementations may includeimplementation in one or more computer programs that are executableand/or interpretable on a programmable system including at least oneprogrammable processor, which may be special or general purpose, coupledto receive data and instructions from, and to transmit data andinstructions to, a storage system, at least one input device, and atleast one output device.

The computer programs (also known as programs, software, softwareapplications or code) include machine instructions for a programmableprocessor and may be implemented in a high-level procedural and/orobject-oriented programming language, and/or in assembly/machinelanguage. As used herein, the terms “machine-readable medium”“computer-readable medium” refers to any computer program product,apparatus and/or device (e.g., magnetic discs, optical disks, memory,Programmable Logic Devices (PLDs)) used to provide machine instructionsand/or data to a programmable processor, including a machine-readablemedium that receives machine instructions as a machine-readable signal.The term “machine-readable signal” refers to any signal used to providemachine instructions and/or data to a programmable processor.

While one or more of the examples described herein relate to fullyautomated manufacturing systems and operations, in one or more otherexamples, the indexing apparatus 100, the manufacturing system 168, andmethods 1000, 2000, 3000 are used with partially automated manufacturingsystems and operations or manual manufacturing systems and operations inwhich the fixture tool 102 is located relative to a work station and amanufacturing machine is indexed relative to the fixture tool 102 forperforming one or more manufacturing operations on the workpiece 170.Such manufacturing operations include subtractive manufacturingoperations, additive manufacturing operations, and assembly operationsperformed on the workpiece 170. In an example, the manufacturingoperation is performed on a post-cure composite material or othermaterial. In another example, the manufacturing operation is performedon a pre-cure composite material, such as composite layup operations andcomposite lamination operations.

Referring now to FIGS. 33 and 34 , examples of the indexing apparatus100, the manufacturing system 168, and the methods 1000, 2000, 3000 maybe used in the context of an aircraft manufacturing and service method1100, as shown in the flow diagram of FIG. 33 and an aircraft 1200, asschematically illustrated in FIG. 34 .

FIG. 34 is an illustrative example of the aircraft 1200. The aircraft1200 includes an airframe 1202 and a plurality of high-level systems1204. Examples of the high-level systems 1204 include one or more of apropulsion system 1208, an electrical system 1210, a hydraulic system1212, and an environmental system 1214. In other examples, the aircraft1200 may include any number of other types of systems, such as acommunications system, a guidance system, and the like. The workpiece170 may be any one of a structure, an assembly, a sub-assembly, acomponent, and a part of the airframe 1202 or the interior 1206. Forexample, the workpiece 170 may be any one of an aircraft spar, a wingsection, a fuselage section, an interior panel, an exterior skin panel,and the like.

As illustrated in FIG. 33 , during pre-production, the method 1100 mayinclude specification and design of the aircraft 1200 (block 1102) andmaterial procurement (block 1104). During production of the aircraft1200, component and subassembly manufacturing (block 1106) and systemintegration (block 1108) of the aircraft 1200 may take place.Thereafter, the aircraft 1200 may go through certification and delivery(block 1110) to be placed in service (block 1112). Routine maintenanceand service (block 1114) may include modification, reconfiguration,refurbishment, etc. of one or more systems of the aircraft 1200.

Each of the processes of the method 1100 illustrated in FIG. 33 may beperformed or carried out by a system integrator, a third party, and/oran operator (e.g., a customer). For the purposes of this description, asystem integrator may include, without limitation, any number ofspacecraft manufacturers and major-system subcontractors; a third partymay include, without limitation, any number of vendors, subcontractors,and suppliers; and an operator may be an airline, leasing company,military entity, service organization, and so on.

Examples of the indexing apparatus 100, the manufacturing system 168,and the methods 1000, 2000, 3000 shown and described herein may beemployed during any one or more of the stages of the manufacturing andservice method 1100 shown in the flow diagram illustrated by FIG. 33 .In an example, implementation of the disclosed indexing apparatus 100,manufacturing system 168, and methods 1000, 2000, 3000 may form aportion of component and subassembly manufacturing (block 1106) and/orsystem integration (block 1108). For example, assembly of the aircraft1200, the airframe 1202, and/or components thereof using implementationsof the disclosed indexing apparatus 100, manufacturing system 168, andmethods 1000, 2000, 3000 may correspond to component and subassemblymanufacturing (block 1106) and may be prepared in a manner similar tocomponents or subassemblies prepared while the aircraft 1200 is inservice (block 1112). Also, implementations of the disclosed indexingapparatus 100, manufacturing system 168, and methods 1000, 2000, 3000may be utilized during system integration (block 1108) and certificationand delivery (block 1110). Similarly, implementations of the disclosedindexing apparatus 100, manufacturing system 168, and methods 1000,2000, 3000 may be utilized, for example and without limitation, whilethe aircraft 1200 is in service (block 1112) and during maintenance andservice (block 1114).

Referring to FIGS. 1 and 34 , also disclosed is a method of fabricatinga portion of the aircraft 1200 (FIG. 34 ) using the indexing apparatus100 (FIG. 1 ) and a method of fabricating a portion of the aircraft 1200using the manufacturing system 168 (FIG. 1 ). Referring to FIGS. 29 and34 , also disclosed is a portion of the aircraft 1200 assembledaccording to the method 1000 (FIG. 29 ). Referring to FIGS. 30 and 34 ,also disclosed is a portion of the aircraft 1200 assembled according tothe method 2000 (FIG. 30 ). Referring to FIGS. 31 and 34 , alsodisclosed is a portion of the aircraft 1200 assembled according to themethod 3000 (FIG. 31 ). The portion of the aircraft 1200 includes one ormore of a structure, a component, a part, an assembly, and asub-assembly of any one of the airframe 1202, the interior 1206, and thehigh-level systems 1204.

As used herein, a system, apparatus, device, structure, article,element, component, or hardware “configured to” perform a specifiedfunction is indeed capable of performing the specified function withoutany alteration, rather than merely having potential to perform thespecified function after further modification. In other words, thesystem, apparatus, device, structure, article, element, component, orhardware “configured to” perform a specified function is specificallyselected, created, implemented, utilized, programmed, and/or designedfor the purpose of performing the specified function. As used herein,“configured to” denotes existing characteristics of a system, apparatus,structure, article, element, component, or hardware that enable thesystem, apparatus, structure, article, element, component, or hardwareto perform the specified function without further modification. Forpurposes of this disclosure, a system, apparatus, device, structure,article, element, component, or hardware described as being “configuredto” perform a particular function may additionally or alternatively bedescribed as being “adapted to” and/or as being “operative to” performthat function.

For the purpose of this disclosure, the terms “coupled,” “coupling,” andsimilar terms refer to two or more elements that are joined, linked,fastened, attached, connected, put in communication, or otherwiseassociated (e.g., mechanically, electrically, fluidly, optically,electromagnetically) with one another. In various examples, the elementsmay be associated directly or indirectly. As an example, element A maybe directly associated with element B. As another example, element A maybe indirectly associated with element B, for example, via anotherelement C. It will be understood that not all associations among thevarious disclosed elements are necessarily represented. Accordingly,couplings other than those depicted in the figures may also exist.

As used herein, the terms “about” and “approximately” refer to orrepresent a condition that is close to, but not exactly, the statedcondition that still performs the desired function or achieves thedesired result. As an example, the terms “about” and “approximately”refer to a condition that is within an acceptable predeterminedtolerance or accuracy. For example, the terms “about” and“approximately” refer to a condition that is within 10% of the statedcondition. However, the terms “about” and “approximately” do not excludea condition that is exactly the stated condition.

In FIGS. 1, 7, 16, 25, 32 and 34 , referred to above, the blocks mayrepresent functional elements, features, or components thereof and linesconnecting the various blocks do not necessarily imply any particularstructure. Accordingly, modifications, additions and/or omissions may bemade to the illustrated structure. Additionally, those skilled in theart will appreciate that not all elements described and illustrated inFIGS. 1-29 , 32 and 34, referred to above, need be included in everyexample and not all elements described herein are necessarily depictedin each illustrative example. Unless otherwise explicitly stated, theschematic illustrations of the examples depicted in FIGS. 1-29, 32 and34 referred to above, are not meant to imply structural limitations withrespect to the illustrative example. Rather, although one illustrativestructure is indicated, it is to be understood that the structure may bemodified when appropriate.

In FIGS. 29-31 and 33 , referred to above, the blocks may representoperations, steps, and/or portions thereof and lines connecting thevarious blocks do not imply any particular order or dependency of theoperations or portions thereof. It will be understood that not alldependencies among the various disclosed operations are necessarilyrepresented. FIGS. 29-31 and 33 and the accompanying disclosuredescribing the operations of the disclosed methods set forth hereinshould not be interpreted as necessarily determining a sequence in whichthe operations are to be performed. Rather, although one illustrativeorder is indicated, it is to be understood that the sequence of theoperations may be modified when appropriate. Accordingly, modifications,additions and/or omissions may be made to the operations illustrated andcertain operations may be performed in a different order orsimultaneously. Additionally, those skilled in the art will appreciatethat not all operations described need be performed.

Further, references throughout the present specification to features,advantages, or similar language used herein do not imply that all of thefeatures and advantages that may be realized with the examples disclosedherein should be, or are in, any single example. Rather, languagereferring to the features and advantages is understood to mean that aspecific feature, advantage, or characteristic described in connectionwith an example is included in at least one example. Thus, discussion offeatures, advantages, and similar language used throughout the presentdisclosure may, but do not necessarily, refer to the same example.

The described features, advantages, and characteristics of one examplemay be combined in any suitable manner in one or more other examples.One skilled in the relevant art will recognize that the examplesdescribed herein may be practiced without one or more of the specificfeatures or advantages of a particular example. In other instances,additional features and advantages may be recognized in certain examplesthat may not be present in all examples. Furthermore, although variousexamples of the indexing apparatus 100, the manufacturing system 168,and the methods 1000, 2000, 3000 have been shown and described,modifications may occur to those skilled in the art upon reading thespecification. The present application includes such modifications andis limited only by the scope of the claims.

What is claimed is:
 1. An indexing apparatus, comprising: a fixturetool, movable relative to an operation cell; an indexing feature, fixedrelative to the fixture tool; a plurality of probes, each one of theplurality of probes comprising a probe head that is movable relative tothe fixture tool to engage the indexing feature; and a controller, incommunication with the plurality of probes, wherein the controller isconfigured to locate the fixture tool relative to the operation cellfrom a plurality of probe locations of the probe head of each one of theplurality of probes, engaged with the indexing feature.
 2. The indexingapparatus of claim 1, wherein the controller is further configured to:determine the plurality of probe locations of the plurality of probes inat least one dimension of a fixed coordinate system; determine anindexing-feature location of the indexing feature in the at least onedimension of the fixed coordinate system from the plurality of probelocations of the plurality of probes; and determine a fixture-toollocation of the fixture tool in the at least one dimension of the fixedcoordinate system from the indexing-feature location of the indexingfeature.
 3. The indexing apparatus of claim 2, wherein the controller isfurther configured to: register a digital model, representing thefixture tool and the indexing feature, to the indexing-feature locationof the indexing feature; and convert a model location of the digitalmodel, registered to the indexing-feature location, to the fixture-toollocation of the fixture tool.
 4. The indexing apparatus of claim 2,wherein the controller is further configured to index an automatedmachine relative to the fixture-tool location of the fixture tool. 5.The indexing apparatus of claim 4, wherein: the fixture tool comprises amandrel, configured to support a pre-cure composite laminate; and theautomated machine is configured to perform a pre-cure manufacturingoperation on the pre-cure composite laminate.
 6. The indexing apparatusof claim 4, wherein: the fixture tool comprises a holding-feature,configured to secure a post-cure composite structure; and the automatedmachine is configured to perform a post-cure manufacturing operation onthe post-cure composite structure.
 7. The indexing apparatus of claim 1,wherein: the indexing feature comprises at least one surface of thefixture tool; and each one of the plurality of probes is configured tomove the probe head into contact with the at least one surface.
 8. Theindexing apparatus of claim 1, wherein: the indexing feature comprisesan interface-index, located on a surface of the fixture tool andcomprising an interfacing-structure; each one of the plurality of probescomprises a contact-index, formed by at least a portion of the probehead configured to mate with the interfacing-structure so that at leasta portion of the contact-index physically engages at least a portion ofthe interface-index.
 9. The indexing apparatus of claim 1, furthercomprising a displacement sensor, in communication with the plurality ofprobes and configured to measure a displacement of each one of theplurality of probes when the plurality of probes engage the indexingfeature.
 10. A method of fabricating a portion of an aircraft using theindexing apparatus of claim
 1. 11. A manufacturing system, comprising:an automated machine, located in an operation cell and configured toperform at least one manufacturing operation; a fixture tool, configuredto support a workpiece and movable relative to the operation cell; anindexing feature, fixed relative to the fixture tool; a plurality ofprobes, each one of the plurality of probes comprising a probe head thatis movable relative to the fixture tool to engage the indexing feature;and a controller, in communication with the plurality of probes and theautomated machine; and wherein: the controller is configured to locatethe fixture tool relative to the operation cell from a plurality ofprobe locations of the probe head of each one of the plurality ofprobes, engaged with the indexing feature; and the controller is furtherconfigured to index the automated machine relative to a fixture-toollocation of the fixture tool.
 12. The manufacturing system of claim 11,wherein the controller is further configured to: determine the pluralityof probe locations of the plurality of probes in at least one dimensionof a fixed coordinate system; determine an indexing-feature location ofthe indexing feature in the at least one dimension of the fixedcoordinate system from the plurality of probe locations of the pluralityof probes; and determine the fixture-tool location of the fixture toolin the at least one dimension of the fixed coordinate system from theindexing-feature location of the indexing feature.
 13. The manufacturingsystem of claim 12, wherein the controller is further configured to:register a digital model, representing the fixture tool and the indexingfeature, to the indexing-feature location of the indexing feature; andconvert a model location of the digital model, registered to theindexing-feature location, to the fixture-tool location of the fixturetool.
 14. The manufacturing system of claim 11, wherein: the fixturetool comprises a mandrel, configured to support a composite laminate;and the automated machine comprises an automated fiber placementmachine.
 15. The manufacturing system of claim 11, wherein: the indexingfeature comprises at least one surface of the fixture tool; and each oneof the plurality of probes moves the probe head into contact with the atleast one surface.
 16. The manufacturing system of claim 11, wherein:the indexing feature comprises at least one interface-index, located ona surface of the fixture tool and comprising an interfacing structure;and each one of the plurality of probes comprises a contact-index,formed by at least a portion of the probe head that is movable relativeto and configured to mate with the interfacing-structure so that atleast a portion of the contact-index physically engages at least aportion of the at least one interface-index.
 17. The manufacturingsystem of claim 11, further comprising a vehicle, configured to supportthe fixture tool and move the fixture tool relative to the operationcell, and wherein the vehicle comprises one of an automated guidedvehicle and a cart, configured to travel along a track, running throughthe operation cell.
 18. The manufacturing system of claim 11, furthercomprising: a second operation cell; a second automated machine, locatedin the second operation cell and configured to perform at least onemanufacturing operation; and a second plurality of probes, configured toengage the indexing feature; and wherein: the controller is incommunication with the second plurality of probes and the secondautomated machine; the controller is configured to locate the fixturetool relative to the second operation cell from a second plurality ofprobe locations of the second plurality of probes, engaged with theindexing feature; and the controller is further configured to index thesecond automated machine relative to a second fixture-tool location ofthe fixture tool.
 19. A method of fabricating a portion of an aircraftusing the manufacturing system of claim
 11. 20. A method ofmanufacturing, the method comprising: moving a fixture tool relative toan operation cell; physically engaging an indexing feature, fixedrelative to the fixture tool, with a probe head of each one of aplurality of probes; locating the fixture tool relative to the operationcell from a plurality of probe locations of the probe head of each oneof the plurality of probes, engaged with the indexing feature; andindexing an automated machine relative to a fixture-tool location of thefixture tool.
 21. The method of claim 20, further comprising:determining the plurality of probe locations of the plurality of probesin at least one dimension of a fixed coordinate system; determining anindexing-feature location of the indexing feature in the at least onedimension of the fixed coordinate system from the plurality of probelocations of the plurality of probes; and determining the fixture-toollocation of the fixture tool in the at least one dimension of the fixedcoordinate system from the indexing-feature location of the indexingfeature.
 22. The method of claim 20, further comprising: moving thefixture tool within a work envelope of the operation cell; and movingthe plurality of probes into contact with the indexing feature.
 23. Aportion of an aircraft assembled according to the method of claim 19.24. The indexing apparatus of claim 1, wherein: the indexing featurecomprises an interfacing-structure that extends longitudinally along asurface of the fixture tool; and at least a portion of theinterfacing-structure and at least a portion of the probe head havecomplementary geometries.